Project overview
Objectives, scope, and technical context.
A new base was established at Essen/Mülheim Airport for Deutsche Zeppelin-Reederei to operate a Zeppelin NT. This historic site combines existing airship infrastructure, a modern hangar, and a central location in the Rhine-Ruhr metropolitan region.
Regular commercial scenic flights have been departing from Essen/Mülheim since May 2024. Safe and cost-effective operations require a reliable supply of helium as the lifting gas.
The engineered solution
Technical, operational, and infrastructural.
The solution used a stationary VAKO helium pressure vessel with a volume of 95 m³, designed to store approximately 700 kg of helium.
The storage solution allows helium to be supplied as needed for maintenance, refilling, and pressure balancing in the airship. Its precise sizing and design minimize losses and ensure efficient operation.
The system was integrated directly at the hangar and configured for long-term service in flight operations.
The challenge
Technical and regulatory core requirements.
Helium is safety-critical and expensive, and it cannot be produced on-site. Airship operations therefore require low-loss storage, safe handling, and precise inventory control.
The project called for a storage solution that would reliably provide the required gas volume, meet the highest standards for leak tightness and safety, and comply with all relevant technical and regulatory requirements.
The infrastructure had to be integrated directly at the hangar and designed for continuous flight operations.
VAKO’s contribution
Engineering and fabrication – all from VAKO.
VAKO handled the development, design, and fabrication of the helium pressure vessel as well as delivery and installation at the site.
The vessel is specifically designed for stationary use in airship operations and meets all relevant technical and regulatory requirements. Leveraging its engineering and fabrication expertise, VAKO ensured that the helium storage solution could be integrated safely, efficiently, and seamlessly into the existing infrastructure.
Results and added value
Reliable performance and long-term benefits.
The current helium infrastructure now provides the Essen/Mülheim site with a reliable, cost-effective foundation for continuous zeppelin operations.
The VAKO storage solution ensures a safe supply of lifting gas and supports stable flight operations. The project demonstrates how specialized pressure vessel technology can make a key contribution to operational safety and efficiency in airship operations.
