How can you plan an entire production hall when no existing data, drawings, or models are available?
This was the challenge Witzenmann faced when the company planned the construction of its main plant in Pforzheim—a 23,700 m² flagship site that, as a smart factory, shapes the future of the company’s production.
Instead of relying on analog cardboard workshops or 2D drawings, Witzenmann opted early for digital planning with Halocline Professional. This allowed all hall layouts, machine zones, and workstations to be fully built, tested, and optimized virtually—long before the first real wall was in place. The project demonstrates impressively how digital planning from the ground up works—with realistic results, efficient collaboration, and strong team acceptance.
The scale and complexity of the new building made it clear: traditional planning tools were not enough.
The goal was to digitally develop a complete production system on a “greenfield” site— without existing layout data or 2D floor plans.
Witzenmann wanted to:
- evaluate different layout ideas directly in 3D space,
- actively involve employees in the planning process,
- assess ergonomic and logistical aspects early on,
- and digitally document the new plant for the long term.
Approach
Step 1: Define the Area and Create the Layout Foundation
To start efficiently, the team created a new project in Halocline and defined the hall area directly in the desktop layout. With the grid and camera view, the area could be structured precisely.
Key steps:
- create a new project area and define the hall dimensions,
- activate the grid to maintain orientation and proportions,
- place basic objects from the library (e.g., machines, shelves, zones),
- scale and label objects to establish the basic structure,
- save the first layout idea as an initial variant.
→ More in the workflow: From Rough to Fine – From Desktop to VR
Step 2: Define Hall Structure and Production Zones
In the next step, the plant layout was further structured. With the 2D view, material flow, production lines, and traffic routes could be arranged systematically. Using the view and camera settings, the team switched between top view, angled view, and perspective to maintain spatial understanding.
Key steps:
- activate the 2D view and structure areas using grid guidance,
- color-code production, logistics, and assembly zones,
- logically separate work areas and define routing paths,
- consider safety distances and movement areas,
- save the layout to keep versions clearly separated.
→ More in the workflow: From Rough to Fine – From Desktop to VR
Step 3: Create Variants – Compare Different Layout Ideas
Since many options are open in a new build, Witzenmann used the ability to create and evaluate multiple variants directly in Halocline. This made it possible to test different machine arrangements, material flows, and workstation clusters in direct comparison.
Key steps:
- duplicate the existing layout to create a new variant,
- make targeted changes (e.g., different routing or machine sequences),
- save and name variants separately,
- use the comparison function to check differences,
- open variants in VR and walk through them directly.
→ More in the workflow: Layout Planning
Step 4: Review and Optimize the Factory Layout in 3D
After creating and evaluating the variants, Witzenmann switched to the 3D/VR view to assess the layout realistically. In this phase, employees and planners could experience the planned hall at full scale, test working distances and sight lines, and provide direct feedback.
Key steps:
- activate the 3D view and enter the space
- check freedom of movement, reachability, and walking paths
- identify bottlenecks and optimization potential
- make adjustments directly in the model
→ More in the workflow: From Rough to Fine – From Desktop to VR
Results and Added Value
With Halocline Professional, Witzenmann was able to:
- digitally build the entire hall without existing planning data,
- develop and evaluate multiple layout variants in parallel,
- actively involve employees and assess ergonomic factors early,
- optimize material flow and avoid bottlenecks already in the virtual model,
- accelerate the planning process and shorten decision phases.
The result is a complete digital plant layout that serves as a reference for all subsequent planning phases—and forms the foundation for the real construction of the new main plant.
Conclusion
The Witzenmann case shows how Halocline Professional enables digital planning of an entirely new hall— without 2D floor plans, CAD models, or physical models. The combination of desktop layout, 2D/3D views, variant management, and the VR experience enables consistent, transparent planning from the ground up. With Halocline Professional, an idea becomes an immersive digital factory—long before it becomes reality.