Production at Aqua free – coordination with system

Whether short-term orders or long-term planning – many threads come together in Aqua free’s production in Hamburg, Germany.

Production manager Enrico Hans ensures that processes run smoothly, hygiene standards are met, and the filters leave the plant on time. When everything in our production runs well, Enrico and his team have done a good job.

For the past three years, the bioprocess engineer has been heading the department that ensures every day that single-use and reusable water filters leave the Hamburg plant on time and in perfect hygienic condition.

A typical working week in production

Every week in production follows a clear structure. At the start of the week, the team sets priorities in a meeting; at the end of the week, everyone reviews the results together and prepares the upcoming tasks.

In between, Enrico focuses on coordinating manufacturing processes, monitoring workflows, and ensuring material availability. If a component is missing or an order is delayed, Enrico and his team react immediately and adapt the processes. This keeps production flexible and reliable – even when time is tight.

Different requirements for single-use and reusable water filters

The requirements are demanding – especially for reusable water filters. Traceability, documentation, hygiene: nothing is left to chance here.

For single-use filters, on the other hand, speed and flexibility are what count.

“We have to be able to react quickly,” says Hans. Short-term orders and tight deadlines are part of everyday production.

Hundreds, sometimes several thousand filters in just one day

How flexible the team really is became clear in a specific case:

A large property company placed a short-notice order for several hundred filters including adapters. Within a very short time, the team coordinated production and packaging – despite limited resources.

One colleague in shipping, a long-standing professional in the team, independently prepared thousands of individual parts ready for dispatch in just one day. A commitment that shows what matters most in production: speed, precision, and teamwork.

Defined structures enable high throughput

Each year, Aqua free produces and reprocesses several hundred thousand filters – this can only be achieved with clear structures. Workflows are tightly scheduled: daily briefings, defined responsibilities, regular training sessions.

Cross-departmental collaboration as a key factor

Enrico works closely with purchasing, quality management, and sales. Reliability, quality, and availability – this only succeeds when everyone pulls together. That is why cross-departmental communication is just as important to him as internal workflows.

Continuous process optimisation for greater efficiency

Further developing processes is also a major focus: energy-saving measures in drying and process improvements for tap filters have already been implemented. Next steps include introducing lean methods and further semi-automated assembly units.

The goal is an increasingly digitalised and professionally automated production setup that is more efficient, transparent, and fit for the future.

About Enrico Hans

Enrico knows production from the ground up. Originally trained as an electrician, he spent ten years working on installations before completing his secondary school diploma at 27 and earning his doctorate in Hamburg. First development, then production – for him, a logical step. “I always enjoyed troubleshooting. But these days, I’m also glad when things run smoothly.”

What makes a good day for him? “When I get on my bike after work and just ride home – without worrying.”

And the team? That motivates him every day: “Finding solutions together, keeping everything running – that’s what makes it fun.”