Plant Engineering

The SBU Plant Engineering specializes in the design, construction, and technological development of industrial plants for storing, conveying, mixing, dosing, and weighing high-quality bulk materials and raw materials. With more than 1,600 employees worldwide, Zeppelin creates solutions for customers in the plastics, chemicals, rubber, and tire industries. The food and beverage industry also values Zeppelin's many years of turnkey experience and technological expertise. From plant design and project implementation to after-sales service, including process optimization, Zeppelin is an integrated solution provider offering complete solutions from a single source. Each plant impresses with its individually implemented customer requirements, smart automation solutions, and comprehensive service. Headquartered in Germany and with over 20 locations worldwide, the SBU enables its customers to conduct product trials on an industrial scale in its own technical centers in order to test and sustainably optimize plant designs. Zeppelin also develops and manufactures components for mechanical and plant engineering that can be seamlessly integrated into third-party plants.

Review

The 2025 financial year was marked by persistently challenging market conditions in the core industries of chemicals, plastics, and food for the SBU Plant Engineering. In Europe in particular, cautious investment and delayed decisions on the part of customers led to subdued demand overall. In contrast, the markets in China and India developed positively and contributed to stabilizing business development.

Despite the challenging environment, the cost and efficiency programs implemented in the reporting year are having a noticeable effect. However, earnings remained under pressure from higher material and energy costs, which weighed on margins.

Significant progress was made in the global supply chain transformation. The targeted expansion of the supplier base, particularly in the polyolefins sector in India, reduced dependence on European procurement markets and strengthened the resilience of supply chains.

At the same time, the fiscal year was marked by internal expenses resulting from comprehensive transformation projects. These included measures to further develop the organizational structure, globalize the company, harmonize processes, and increase efficiency. At the same time, a cultural and mindset shift towards greater customer focus was driven forward. These investments in structures and capabilities formed the basis for the SBU's future competitiveness.

Outlook

Building on the progress made in the 2025 fiscal year in cost and efficiency programs and supply chain transformation, a cautious market recovery is expected for 2026, particularly in the second half of the year in North America and Europe. However, against the backdrop of continuing economic volatility, the outlook remains uncertain. In the future, consistent focus on customer requirements will remain a key priority, particularly with regard to efficient project implementation and high process stability. The aim is to support customers even more effectively through technological expertise, scalable digital solutions, and a high-performance service offering.

The strategic focus is on profitable growth through the further expansion of the technology and service business. In addition, the global transformation agenda will be continued in order to further leverage efficiency potential, scale digital solutions, and strengthen global engineering and supply networks.

Another focus is on expanding sustainable plant solutions, particularly in the areas of recycling, CO₂ reduction, and energy efficiency. At the same time, the portfolio is being reviewed and focused in a targeted manner: Concentration on core technologies and selective withdrawals from low-margin business areas will ensure long-term profitability.

The positive attitude of management and teams supports this course. The ongoing change is being actively shaped as an opportunity for further development. The goal for 2026 is to achieve stable profitability and ensure sustainable value creation within the international group.

Successful orders

In fiscal year 2025, the Plant Engineering strategic business unit secured an important order in the area of plant modernization for a petrochemical production plant in Saudi Arabia. The scope of services includes the delivery of plant components to finalize the production process, including a pneumatic conveyor system and pellet silos. The order is based on the modernization of an existing plant that was previously implemented by Zeppelin Systems. This order success underscores the long-term confidence in the company's technological expertise and performance.

In addition, Zeppelin Systems won a major order for the construction of a new polypropylene plant in India. The project includes a pneumatic conveying system and pellet silos as part of a large-scale petrochemical complex. With this project, the Strategic Business Unit is strengthening its position in the international petrochemical business and confirming its expertise in the implementation of technologically demanding large-scale projects.

Another milestone was reached in the tire market in the Gulf region. Zeppelin Systems GmbH and Zeppelin Systems Italy SpA, with regional support from Zeppelin Systems Gulf Co. Ltd, are jointly implementing the central plant technologies for a new, state-of-the-art mixing plant in the United Arab Emirates. The scope of supply includes essential components for material storage, conveying, dosing, and feeding in the mixing room. The project makes an important contribution to industrial tire production in the region and strengthens Zeppelin Systems' position as a leading partner in the global construction of tire production plants.

Product innovations

In 2025, the focus was on solutions for mass battery production. The Feeding & Dosing Unit (FDU) was continuously developed and covers applications from laboratory scale to industrial series production. Thanks to investment in a modern hazardous materials technical center in Germany, battery tests can now be carried out under safe conditions and processes can be optimized for industrial use at an early stage.

To convey highly abrasive bulk materials, Zeppelin Systems expanded its product portfolio with new VST-C and TST-C ceramic diverters. The highly wear-resistant aluminum oxide ceramic used enables the safe transport of even highly abrasive powders with a Mohs hardness of up to 9. This increases the service life of plant components and sustainably improves the efficiency of conveying processes.

In addition, Zeppelin Systems introduced a new generation of rotary valves (DFM). The advanced models replace the previous ones and offer improved functionality and larger sizes. They enable reliable, efficient, and flexible conveying of powders and granulates, thereby contributing to increased performance of existing and new plants.

In the field of plastics recycling, an innovative solution was introduced in the form of the DEO-L mobile deodorization unit. The unit enables the degassing and odor reduction of plastic recyclates on a laboratory scale with industrial performance. Through realistic simulation of the process steps of heating, degassing, and cooling, the DEO-L provides reliable data for the design of industrial plants and supports customers in scaling sustainable recycling processes.

Events and Awards

Zeppelin Systems presented its technological expertise in the food, malt, battery, plastics, and rubber industries at leading international trade fairs such as iba, Battery Show Europe, drinktec, and K 2025. The trade fair appearances provided an important platform for professional exchange with customers and partners and delivered valuable impetus for future projects and product developments.

In addition, the Plant Engineering SBU strengthened its innovative power by expanding its technical center in Shanghai, including a new bulk solids laboratory and modern measurement methods for material characterization. Participation in national and European research projects such as GUTBatt and GIGABAT underscores the importance of the business unit as a technological development partner, particularly in the area of sustainable battery production and raw material efficiency.

The Fresh-Tec initiative has also set new standards in the plastics recycling industry. The implementation of world-leading deodorization plants for post-consumer polyethylene pellets underscores the company's technological capabilities and its role in the development of energy-efficient and sustainable plant solutions.