ZPRE — pressure equipment, vessels and heat exchangers, large-scale CNC machining | Stanowice near Olawa, Poland

KOMPETENCJE

Process equipment

Projektujemy i produkujemy wg PED, EN 13445, ASME.

1 / 4
17 yrs
of experience in industrial projects (since 2009)
50+
WPQR procedures — pressure equipment to PED Module G cat. IV, EN 13445-5 and ASME VIII Div.1, full UDT authorisations
200+
delivered apparatus, assemblies and components
10 t
large-format CNC machining centres

Pressure equipment, machine components and large-size welded-and-machined assemblies — one-off and small-batch production, repairs and upgrades. We do not make mass-produced structures — we do what is difficult: products accepted by quality control and notified bodies, where quality and on-time delivery come first.

About us

An engineering and manufacturing plant for demanding projects

Since 2009 we have combined design, welding and CNC machining under one roof. We work with clients for whom risk, documentation and quality matter more than the lowest price.

ZPRE production hall — ABUS overhead crane, heat exchangers on stands, CNC gantry milling machine in the background

Engineering thought before the first cut

Zakład Produkcyjno-Remontowy Energetyki was founded in 2009. Since 2020 our headquarters has been located in a newly built production and office hall in Stanowice (Oława county, Poland).

Every project is handled individually — from the enquiry and quotation, through manufacturing, documentation and final inspections. All design, manufacturing and inspection processes are carried out under one roof — which reduces outsourcing and transport between locations and, as a result, shortens the lead time. For the client — one team = one point of responsibility.

We work in a one-off and small-batch production model, most often for the power, chemical and process industries, as well as for machine manufacturers (OEM). We build pressure vessels to PED Module G cat. IV, EN 13445-5 and ASME VIII Div.1, with full UDT authorisations. We are not limited to the areas listed above — we are ready to take on the challenge in other industrial sectors as well.

Our goal is not to sell the lowest price. Our goal is certainty of schedule, certainty of geometry, certainty of documentation and, above all, quality and safety.

Facts 17 years of experience — since 2009
Goal Quality, Safety, On-time delivery
Specialisations

The pillars of our business — from design to a finished, documented product

Welding, CNC machining, assembly and quality control under one roof mean less outsourcing, less risk and a shorter lead time. We sell not just a product, but the value that comes from our expertise, many years of experience and expert support at every stage of cooperation.

1300-E pressure vessels ready for delivery in the ZPRE production hall
Process equipment · PED cat. IV

Process and pressure equipment

New production as well as upgrades and bundle replacements. Expertise built since 2009 on demanding projects for the power and process industries.

  • Heat exchangers, coolers, vessels, process apparatus
  • Tube bundles, tubesheets, headers and manifolds
  • Upgrades, tube-bundle replacements, modifications
  • Alloy steels, duplex, super duplex, nickel and copper alloys
CNC milling of a welded assembly with coolant — machining of an OEM component
Components · OEM

Components and assemblies for OEM

A contract manufacturer of welded and machined assemblies for machine builders and integrators — from single components to complete, ready-to-install modules.

  • Welded structures from heavy plate
  • Assemblies machined after welding (geometry retained)
  • Frames, bases, bodies, load-bearing elements
  • Large-size parts up to 3.1 × 2.1 m and 8 tonnes
Copper winding on a positioner — a rotating-machine component with full traceability
Rotating machinery · traceability

Specialist and demanding components

Components for rotating machinery and sectors requiring full traceability from material to acceptance — made to the client’s documentation, in exotic alloys, with precision not available in a typical workshop.

  • Generator windings, turbine and rotor parts
  • Components made to the client’s documentation
  • Exotic materials: copper, nickel alloys, super duplex
  • Full traceability: power, aerospace, defence
On-site heat-exchanger retubing — tube replacement at the tubesheet using hydraulic equipment
Repairs · Upgrades

Heat-exchanger retubing

Our experience and technologies also allow us to carry out repairs and upgrades of heat exchangers on site. We have state-of-the-art equipment which, combined with our experience, lets us replace some or all of the damaged tubes in a short time.

  • Tube replacement in under-turbine heat exchangers
  • Repairs of water-to-water heat exchangers
  • Repairs of high-pressure heat exchangers
Capabilities & quality

A real machine park and quality built into the process

We build quality into the process — we do not inspect it only at the end. Inspection accompanies every stage: from technology preparation, through welding and machining, to final acceptance.

Operator at a CNC machine control panel in the ZPRE production hall

Production & machining

  • Production hall 1000 m² (11 m high), 10 t overhead crane
  • 2× Hartford PRO-3210 CNC gantry milling machine (X 3100 × Y 2100 × Z 1000 mm, 8 t table)
  • CNC vertical turning lathe — machining up to ⌀ 1600 mm
  • One-off and small-batch production

Welding & forming

  • MIG/MAG, TIG
  • Orbital / mechanized welding (Polysoude PS406 + PS204)
  • Plate rolling and forming
  • In-house WPS/WPQR procedures — manual, semi-automatic, automated

Certificates & authorisations

  • 7× PED Module G cat. IV (TÜV Rheinland) — the highest category of the Pressure Equipment Directive
  • Manufacturing to EN 13445-5:2021 and ASME VIII Div.1
  • Full UDT authorisations (manufacturing, upgrade, repair)
  • Welding Coordinator on the team

Thermosetting coatings · Novotherm

  • Resin-based coatings Novotherm 405/410/420
  • Resistant to fuels, oils and process chemicals
  • In-house paint booth + curing oven 180-200°C
  • Full cycle: shot blasting → priming → coating → thickness inspection
Technologies

The processes and methods that complete a project

Welding, machining and quality control in one plant. Every technology is based on our own WPS/WPQR procedures and operated by qualified personnel.

Metal forming

We have our own forming technologies for tubes and plate, used both for making heat-exchanger U-tubes and very complex components for turbogenerators and OEM. We also fabricate vessel and header shell sections and use dozens of tube-bundle expansion technologies.

Welding & heat treatment

We have 3 welding stations equipped with branded gear from Lorch, Kemppi, Polysoude, Cowley and Schermann. For weld treatment we use our own 6-channel resistance heat-treatment unit. In total we hold over 50 welding and heat-treatment procedures.

Inspection & documentation

Dimensional inspection and VT in-house; PT/MT/UT/RT through partners. Material certificates 3.1/3.2 (EN 10204), full traceability, PED cat. IV documentation (TÜV Rheinland), EN 13445-5, ASME VIII Div.1.

How we work

Five steps from enquiry to acceptance

1

Enquiry

Enquiry with documentation (PDF / DWG / STEP).

2

Technology

Defining the technology and scope of work.

3

Quotation

Quotation and delivery date.

4

Production

Production with in-process quality control.

5

Acceptance

Acceptance and delivery with full documentation.

Industries

Power as the foundation, but not the limit

We built our expertise in the power and process industries. The same processes — design, welding, large-size machining, PED documentation — open us to any industry where quality costs more than a mistake.

Refinery/petrochemicals at sunset — the process sector we work for

Currently

  • Power — heat exchangers, coolers, generator and turbine components, upgrades, bundle replacements
  • Chemicals & petrochemicals — process equipment, vessels, manifolds; alloy steels, duplex
  • Machine building / OEM — frames, bodies, bases, assemblies machined after welding
  • Process industry — tube bundles, tubesheets, cat. IV pressure equipment
Rail, aerospace and R&D — sectors we are open to

Open to

  • Rail & heavy transport — welded assemblies, load-bearing frames, machined sub-assemblies
  • Aerospace — components requiring full traceability and welding procedures
  • Defence — assemblies made to the client’s documentation, with 3.1/3.2 certificates
  • Space & R&D — one-off and prototype production
Projects

Selected projects from our workshop

Categories of products in which we have built expertise since 2009. Each photo represents a real project with documentation and acceptance. Project descriptions are shown in Polish.

Aparatura procesowa
Komponenty generatorów oraz maszyn OEM
Remonty i modernizacje
Team

Who you’ll be talking to

Straight to the people who run your project — from the first quotation, through technology, to final acceptance.

MK
Michał Kozłowski
General Director
PK
Piotr Knych
Technical Director
MC
Michał Ciastoń
Operations Director
BG
Brajan Głąb
Production Engineer
JT
Jakub Turek
CNC Programmer
DB
Dariusz Bruliński
Welding Engineer
Contact

Let’s talk about your project

If you are looking for a stable, quality-focused manufacturing partner, we will be glad to discuss your requirements. A short project description together with technical documentation (PDF / DWG / STEP) will let us quickly assess the scope and feasibility.

  • We review every enquiry individually
  • We advise on the choice of technology and manufacturing solutions
  • References available on request

Please send attachments (PDF / DWG / STEP) to our e-mail address after submitting the enquiry.