New Concrete Pipe Production strengthens the Nisterau Location

P.V. Betonfertigteilwerke GmbH has expanded production at its Nisterau facility with a Radialpresse RP 1230-5 pipe production line from Prinzing Pfeiffer. The first product – a DN 1,000 concrete pipe – was manufactured in early June 2026 in accordance with the FBS quality guidelines. The new plant was then officially opened at the end of June. In addition to the new machinery, the investment includes a purpose-built facility, a concrete mixing plant, and other production and testing equipment.

A plant designed from the ground up as a cohesive whole

P.V. Betonfertigteilwerke is part of an owner-managed group of companies with 16 locations in Germany, Poland, and Hungary. The company develops and manufactures precast concrete components for civil engineering and building construction. From its original focus on shaft construction, the company has evolved into a comprehensive systems provider through the expansion of its product portfolio and the growth of its network of locations.

In Nisterau, the existing production facility was extensively expanded. The project includes a production hall spanning approximately 5,000 m², a new concrete mixing plant, a testing line for concrete pipes, a rebar welding machine, and additional plant equipment. The production environment was designed so that machinery, material flow, and operational processes are seamlessly coordinated. It creates additional capacity for concrete and reinforced concrete pipes for sewer systems and pipelines, which are manufactured in accordance with the heightened requirements of the FBS quality guideline.

Therefore, the investment decision was not based solely on the machine’s performance specifications. Equally important was how the manufacturing solution could be integrated into the new building, the mixing and conveying systems, and the plant’s operational processes.

From Planning to Installation

Discussions about the project began in November 2024. From P.V.’s perspective, factors that weighed in favor of Prinzing Pfeiffer included the long-standing business relationship and experience with an older radial press from the manufacturer at the Kluczbork site in Poland. The ability to tailor the machine and molding equipment to the planned pipe production in Nisterau was also a key factor.

The project kicked off in late July 2025 with a joint on-site meeting. The team assessed the structural conditions and coordinated the plant layout as well as the interfaces with the supplementary components and the building contractor. Requirements regarding the foundation, installation area, access points, transport routes, and utility connections were thus incorporated into the further planning at an early stage.

Prinzing Pfeiffer’s project management team coordinated the consultations between P.V. and the technical departments involved, tracked deadlines and dependencies, and followed up on outstanding issues. During installation and commissioning, the project managers, foremen, and P.V. contacts held weekly meetings. This allowed questions regarding the interfaces between the machine, the mixing plant, the molding equipment, and the production process to be resolved promptly.

The RP 1230 was manufactured at Prinzing Pfeiffer’s production site in Porta Westfalica and thoroughly tested before shipment. The inspections included testing mechanical functions, electrical components, and the control software.

Delivery to Nisterau began in late February 2026. By mid-March, the required foundation pit had been completed and approved; preparations for installation could then begin. Two mobile cranes were used for hoisting the unit into place. The system was positioned on the foundation inside the hall without the need to open the hall’s roof.

After alignment and securing, the mechanical, electrical, and hydraulic systems were finalized. Assembly and commissioning proceeded swiftly. Acceptance and handover took place at the end of June 2026.

Pipe range from DN 300 to DN 1,200

The fully automatic RP 1230 radial press is designed for the production of reinforced and unreinforced concrete pipes. In Nisterau, P.V. manufactures pipes for sewer systems and lines in nominal diameters ranging from DN 300 to DN 1,200. In addition to the standard product line, the company can also produce custom products, including fitting pipes in tapered/tapered and tapered/bell configurations.

Innovative Features for Operation, Monitoring, and Changeovers

The RP 1230 combines machine operation functions with tools for production analysis and spare parts management. The Next Base control system supports operation via visualizations and the monitoring of process flows. Self-diagnostic functions help isolate malfunctions. Web-based access and ERP integration facilitate integration into the operational environment.

The Data Analyzer collects production data such as cycle times, piece counts, and machine statuses. The data is structured in a Microsoft SQL database and can be accessed via a web-based interface on a PC, tablet, or smartphone. In addition to standard reports, customer-specific analyses are possible – ranging from hourly to annual overviews. Production, downtime, and wait times are also logged. The data can be exported as CSV or XML files for further processing.

Smart Parts supports the identification of mechanical and electrical components. The digital spare parts documentation links 3D models with interactive circuit diagrams; required parts can be requested directly online.

The equipment is complemented by the semi-automated QCS quick-change system for changing nominal diameters. Coordinated auxiliary devices and racks for insert rings and profile rings significantly reduce changeover time.

Molds and Press Considered Together

The scope of delivery also includes mold jackets for concrete and short pipes from MSM Formenbau GmbH in Langenhahn. The company is a wholly owned subsidiary of Masa GmbH. It has been active in concrete mold and formwork construction since 1963 and was founded under the name Pfeiffer Maschinenfabrik, which is well-known throughout the industry. By coordinating mold design and machine planning, the mold design, the press, and the other mold components could be jointly aligned with the planned production.

From the First Pipe to Full-Scale Production

With the production of the first DN 1,000 pipe on June 10, 2026, the new facility was put into production for the first time. The processes were then further fine-tuned.

On June 24, 2026, P.V. Betonfertigteilwerke officially opened the expanded production facility. Acceptance and handover of the plant followed at the end of the month. This integrated the production hall, mixing plant, rebar and pipe handling systems, and radial press into the production process.

The RP 1230 marks the first time in more than 25 years that a machine of this type has been installed in Germany. For P.V., it expands production capabilities in Nisterau and supports the supply of infrastructure projects in the Rhineland, the Rhine-Main region, and beyond.

The project demonstrates what matters most in an investment of this magnitude: The press must be compatible with the product range and work in harmony with the molds, mixing technology, and plant processes. P.V. Betonfertigteilwerke and Prinzing Pfeiffer were able to draw on a long-standing partnership. From the machine’s design and the mold equipment to regular coordination during assembly and commissioning, the teams worked together to develop a solution tailored to the specific needs in Nisterau. Even after commissioning, Prinzing Pfeiffer remains the point of contact for technical questions and further coordination.