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Our Design Philosophy — Engineering You Can See

At regaco, design is not decoration. It is the discipline that turns complex gas and CO₂ technology into equipment that is safer to operate, faster to install, easier to service — and manufactured in Denmark at a competitive price.

NORDKAP renewable gas compressor station by regaco at a Danish biogas plant

More than 10 years of partnership with Rune Balle Design

Behind every regaco product stands a design partnership that has lasted more than a decade. Since the first NORDKAP compressor station, we have worked side by side with industrial designer Rune Balle of Rune Balle Design — a collaboration so close that design and engineering have become one process, not two.

Industrial designer Rune Balle with the SHERFILL-CNG filling station he designed for regaco

Rune ensures thorough registration and measurement before any project begins. Ideas then take shape through hand sketches, 2D drawings and renderings in soft pencil and marker, cardboard mock-ups and 3D print models — before the design is finalised in SolidWorks and tested intensively with the people who will operate and service it. The pencil renderings below show the SHERFILL filling post and the SHERPARK-CO₂ transfer system taking shape on paper.

Hand sketch and pencil rendering from the SHERFILL design process Industrial design prototyping of the SHERPARK-CO2 transfer system with marker drawings

The result is a design language that is unmistakably Sherex by regaco. From compressor stations to filling posts to CO₂ transfer systems, our equipment is recognisable at a glance: clean sheet-metal geometry, honest materials, rounded corners and details that make daily operation self-evident. Ten years of continuity in design means our customers always know what they are getting.

Visit runeballe.com to see the design stories behind our products.

Designed for harsh weather — and for the whole lifetime

Our equipment lives outdoors: at biogas plants, CNG refueling stations for heavy-duty vehicles, and CO₂ transfer sites for carbon capture, utilisation and storage (CCUS). It must perform around the clock, in rain, frost and salt air.

That is why every regaco product is designed for the Scandinavian climate from day one. Where much of the industry houses compressor plants in converted shipping containers — which corrode, limit equipment size and force technicians to work outdoors in all weather — our NORDKAP concept is a purpose-built machine enclosure on a prefabricated foundation. High-quality sandwich panels, corrosion-resistant materials throughout, and interiors optimised so all maintenance and service take place indoors.

Three priorities run through every design decision:

  • Efficient installation. Everything is prefabricated at the factory, arriving on site as a finished unit on a prefabricated foundation — minimal on-site assembly, swift commissioning, no expensive civil works. A NORDKAP station is lifted into place by crane and ready for commissioning in days, not months.
  • Efficient service and maintenance — for the entire lifetime. Indoor service on NORDKAP means maintenance happens on schedule, not when the weather allows. Sherex filling posts are built so hoses can be changed or serviced without shutting down the station. Electrical rooms accommodate both PLC controls and the customer’s own metering panels.
  • Design for manufacturing. We design around our core production processes — laser cutting and bending — and systematically design out manual operations. One example: the rounded roof corners on NORDKAP are laser-cut plates, bent and spot-welded. What a sheet-metal worker would traditionally build up by hand over many hours is produced in a fraction of the time. That is how we keep production in Denmark at a competitive price.
Prefabricated NORDKAP compressor station lifted by crane during installation on site

Built to last — a circular design story

Durable design is sustainable design. Because our equipment is built in corrosion-resistant materials and designed for lifelong service, it does not wear out when a project ends.

We have several examples of plants we have bought back, refurbished and redeployed in new projects — a genuinely circular life cycle that reduces waste, conserves materials and gives our customers a better total economy. The photo below shows exactly that: a refurbished NORDKAP station being lifted onto its new site, ready for a second working life. When a compressor station can serve a second project as well as it served the first, the design has done its job.

Refurbished NORDKAP compressor station lifted by crane onto its new site for a second project

What our customers get out of it

  • Lower total project cost. Prefabrication, minimal civil works and design for manufacturing keep budgets under control — even with production in Denmark.
  • Equipment that fits the project. NORDKAP dimensions adapt to each customer’s project without the budget slipping. We have delivered more than 20 plants from 18 m² to 45 m² — as stand-alone units, as two plants coupled on site, and as shared buildings with a plant integrated in each end.
  • Uptime by design. Service-friendly details throughout mean maintenance is fast, safe and independent of the weather.
  • A recognisable, long-lasting identity. A design language refined over ten years, with a residual value that makes buy-back and redeployment possible.

One design language across the green gas value chain

The same philosophy runs through everything we deliver: NORDKAP renewable gas compressor stations, SHERFILL-CNG and SHERHOSE-CNG for bio-CNG refueling of heavy-duty fleets, and SHERHOSE-CO₂ and SHERPARK-CO₂ for the safe transfer of liquefied CO₂ in CCUS infrastructure.

Planning a compression, refueling or CO₂ project? Contact our team — or explore our Sherex products and engineering solutions.