Fastener + Fixing Magazine #120 by Fastener + Fixing Magazine

In this issueâ&#x20AC;¦ Made in Germany Tapes + adhesives Lightweight technology fastenerandfixing.com | Issue 120 November 2019

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CONTENTS INDUSTRY NEWS

10-40

Financial reports, acquisitions and trade duty news

COVER STORY 42-43

Guaranteed quality with Ambrovit

CONSTRUCTION FIXINGS

94-114

The speed of serial fixing with manual precision and safety 12 myths and facts on hEN and EAD Famous Failures Series: Part 2 – hydrogen embrittlement

MANUFACTURING TECHNOLOGY

116-128

MANAGEMENT + SYSTEMS

130-138

APPLICATION TECHNOLOGY

140-156

PRODUCTS + TOOLS

158-176

80 years in the name of innovation 145 years of innovative metal forming solutions Carlo Salvi celebrates its 80 th anniversary

MADE IN GERMANY

Face2Face: Dr Stefan Beyer, general manager at DSV Böllhoff – investing in the future Felo stands for quality Puehl: Strengthening the family bond Max Mothes the manufacturer Eurotec – evolution not revolution

44-79

Warehouse robotics for all UK businesses Smart warehousing – how it benefits a business

A wind-win solution Holding it together How was the world’s strongest bolt developed?

EXHIBITIONS

Small but rather well formed Exhibitors get behind Fastener Fair Turkey

80-92

FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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EDITORIAL Part of the Mack Brooks Group Romeland House, Romeland Hill, St Albans, Herts, AL3 4ET, UK

Will Lowry, editor, Fastener + Fixing Magazine

Tel: +44 (0) 1727 814 400 www.fastenerandfixing.com

Key German insight

With a slowdown within the market, and the German economy in general, our ‘Made in Germany’ feature provided the perfect opportunity for the magazine to visit key fastener manufacturers to see how they were handling the changing market conditions.

y first stop was to see Dr Stefan Beyer, general manager of Deutscher Schraubenverband (German Fastener Association), who not only spoke about the objectives of the association, but also the current climate within the German fastener market. I also had the privilege of once again visiting Böllhoff’s impressive headquarters in Bielefeld, to speak to co-CEO Michael Böllhoff about the strategy behind the Group’s recent €172 million infrastructure investment and the benefits it will offer. Other highlights during my trip included meeting Panos Spryidis who recently became the chair of fastening technology for the faculty of architecture and civil engineering at TU Dortmund University – who focused on the role fastening technology plays within the university’s curriculum; Matthias Bierbach explained BiERBACH’s new strategy to switch to the production of specialised nails; and I found out more about Felo – a leading specialist in screwdrivers and screwdriver bits. During the trip I also had the opportunity to find out how Max Mothes became a manufacturer of high performance technology; see first-hand the benefits of GESIPA®’s completed ‘Evotion’ project; as well as meet Ralf and Goetz Kaltheuner – the fourth generation of the family behind Puehl – and discuss why they are joining the operational board from 2020. Also in this issue, our Cover Story concentrates on Ambrovit and how the Italian-based company is meeting customers needs through its vast stock quality and its commitment to guarantee quality. Plus, in response to the article ‘CE Marking on post-installed fasteners: Why not a European Standard’ – which was published in our September edition, Thomas Holland-Letz from Construction Fixings Europe looks at whether the standardisation of post-installed fasteners would actually be the ‘magic bullet’, as well as myths and facts on hEN and EAD. Another excellent article within the Construction Fixings section is from Ryan Murphy, technical director at Evolution Fasteners (UK) Ltd, who carries on his ‘Famous failures series’, this time concentrating on hydrogen embrittlement. Magdalena Grzelak, chief communication manager at Rawlplug, also focuses on the 2 nd generation SC-40 II and how it can offer both the speed of serial fixing, with the precision and safety of manual installation. There is also plenty more news and insight as well, so make sure you don’t miss anything.

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Publishing Director Jamie Mitchell jamie.mitchell@fastenerandfixing.com Executive Editor Phil Matten phil.matten@fastenerandfixing.com Editor Will Lowry will.lowry@fastenerandfixing.com Deputy Editor Claire Aldridge claire.aldridge@fastenerandfixing.com Sales Manager Mac Rahman mac.rahman@fastenerandfixing.com Business Development Manager – Italy Emiliano Pagliaroli emiliano.pagliaroli@fastenerandfixing.com Business Development Manager – Europe Peter Makin peter.makin@fastenerandfixing.com Production & Design Manager Lee Duskwick lee.duskwick@fastenerandfixing.com Digital Content Assistant Grant Rebecca grant.rebecca@fastenerandfixing.com Find us online: @fastenerfixing FastenerandFixingMagazine fastener---fixing-magazine Fastener and Fixing Fastener + Fixing Magazine is a dedicated, trade–only publication which is circulated freely throughout the European trade. Disclaimer The Publisher cannot be held responsible or, in any way, liable for errors or omissions, during input or printing of any material supplied or contained herein although the utmost care is taken to ensure that information contained is accurate and up to date. The Publisher also cannot be held liable for any claims made by advertisers or in contributions from individuals or companies submitted for inclusion within this publication. The opinions expressed are not necessarily those of the Editor or Fastener Fairs Ltd. Copyright Entire contents copyright © Fastener Fairs Limited 2019. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior permission of the publisher.

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FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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INDUSTRY NEWS

Bufab grows despite weaker market Bufab Group reported third quarter net sales of SEK 1.044 billion (€97.6 million), an increase of 17% over the same period in 2018 but with only ‘slightly positive’ organic growth. Sales for the first nine months of the year grew by 14%, with organic growth at 3%.

perating profit (EBITA) for the quarter rose to SEK 89 million (2018 Q3: SEK 81 million) with an operating margin of 8.5% (2018: 9.1%). At the beginning of the third quarter 2019, Bufab completed the acquisition of HT BENDIX A/S with annual sales of around SEK 500 million. Net sales for the first nine months of 2019, increased 14% to SEK 3.223 billion, (2018: SEK 2.82 billion) including 3% organic growth. Order intake grew in line with sales. EBITA for the nine months rose SEK 311 million, from SEK 285 million for the same period in 2018. The operating margin over the nine months for 2019 was 9.6% (2018: 10.1%). President and CEO, Jörgen Rosengren, commented: “During the third quarter, Bufab experienced a clearly weaker demand than earlier in the year and compared with 2018. Nonetheless, sales, operating profit and cash flow increased compared with a strong third quarter 2018. This development was mainly attributable to positive contributions from acquired companies.” He went on to explain that weaker demand was particularly noticeable in Sweden, eastern Europe, and China, due to lower production among many customers, as well as customer destocking. Bufab’s International segment increased market share but experienced lower growth. Operating profit and margin declined

‘somewhat’ during the quarter but increased over the first nine months of the year. In Sweden, the slowdown was stronger and resulted in negative organic growth despite retained market shares. ‘Comprehensive’ price increases strengthened the Q3 gross margin compared with the first half of 2019 and 2018. Bufab’s two recent acquisitions “performed well, which, combined with effective cost control, facilitated a strong increase in operating profit despite the weaker market”. Jörgen Rosengren said Bufab continued to “search for attractive acquisition candidates that can contribute with growth synergies, customer relations, supplier bases and expertise”. Reflecting on market conditions he commented: “The former uncertainty regarding demand was replaced in the quarter by a clear, but nonetheless limited slowdown. This situation presents challenges and opportunities.” Stricter cost control and efficiency enhancement, including digital tools developed in recent years, are being deployed to address weaker demand. On the opportunity front, Jörgen Rosengren sees lower demand enabling purchasing savings, which will be a strong focus during the coming year. He also noted that requirements to improve customer productivity puts weaker competitors under pressure and makes acquisition candidates more inclined to sell.

Challenging business environment, says Bossard Bossard Group says it continued to face challenging market conditions in Q3 2019. Sales in the quarter were up 2.7% year-on-year to CHF 218.5 million (+3.2% in local currency). American business conditions were difficult.

or the first nine months, Bossard posted sales of CHF 669.4 million (€608.4 million), an increase of 1.6% (+2.7% in local currency). Adjusted for acquisitions, sales declined 0.6% year-on-year in local currency. In spite of the waning economy, and the economic tension between the USA and China, Bossard recorded sales growth in both Europe and Asia. In America, however, the Group battled persistent headwinds. Bossard says the economic environment in Europe is becoming more challenging. Third quarter sales rose 8.1% to CHF 127.1 million (+9.6% in local currency). The increase includes the acquisition of Boysen, consolidated since July 2019. Adjusted for acquisitions, third quarter growth was 1.6% in local currency. In the first nine months, European business grew 3.6% to CHF 391.9 million (+6.4% in local currency). Excluding acquisitions sales were up 2.1% in local currency. Bossard described American business conditions as difficult. Net sales declined 10.9% to CHF 53.8 million (-11.8% in local currency). Bossard identifies several reasons. Some customer projects, stimulating growth in 2018, were finally concluded. The slowing economy also led to lower demand from a number of major customers. Additionally, the product mix of the largest US electric vehicle manufacturer has changed markedly since the introduction of its new model series, driving sales down. Bossard says the effects of the trade dispute between the USA and China are becoming increasingly tangible in Asia. The Group was still able to increase Q3 sales by 8.4% to CHF 37.6 million (+8% in local currency). The continued growth is also due to previous years’ investments in expanding the distribution network and in modernising infrastructures. In the first nine months, Bossard posted growth of 9.2% in Asia (+11.4% in local currency). Without acquisitions the increase was 5.9% in local currency. Bossard expects full year sales full year between CHF 860 million and CHF 880 million (2018: CHF 871.1 million) with an EBIT margin at the lower end of the target range of 10% to 13%.

FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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D I S T R I B U T O R S 25.09.19 11:00

INDUSTRY NEWS

Bulten earnings hit hard in Q3 Bulten AB confirmed automotive markets continued to decline into Q3, with weaker demand reflected in the company’s volumes. Earnings were hit hard by lower production levels, restructuring in Germany and relocation in China. Order books improved but president and CEO Anders Nyström remains cautious.

ulten reported third quarter sales of SEK 718 million (€67.1 million), down -0.6% on the same period in 2018. Order bookings were up 7.3% on the same period last year and together with the marginal fall in sales were indicative, said President and CEO Anders Nyström, that deliveries of already contracted business had now begun. Restructuring at Bergkamen, Germany, began during Q3 with costs burdening earnings by SEK 20 million. Restructuring is expected to bring annual savings of around SEK 25 million from 2020 calendar year. Relocation of Chinese production from Beijing to Tianjin is scheduled to complete in the fourth quarter. Expected to create new growth opportunities, in the short term it negatively affected Q3 operating earnings by SEK 7 million. As a result, EBIT was SEK -8 million (2018: SEK 38 million) equating to an operating margin of -1% (Q3 2018: 5.2%). Adjusted EBIT was SEK 19 million, equating to a 2.8% margin. Bulten reported January to September sales at SEK 2.3 billion, a year-on-year decrease of -3.2%. EBIT totalled SEK 71 million (2018

nine months: SEK 162 million) equating to an operating margin of 3.1% (2018: 6.8%). Earnings after tax were SEK 44 million, down from SEK 113 million for the same period in 2018. Anders Nyström commented: “Market development and balancing of inventory levels have resulted in a continued low production rate. The under absorption had a negative impact on earnings of approximately SEK 18 million during the quarter. Customers’ volume reductions at short notice have countered the impact of inventory reduction measures to some extent.” He noted order bookings increased 7.3% during Q3 but cautioned that market uncertainty made development in coming months difficult to predict, so Q4 production could also be affected. Bulten has previously announced new contracts worth just over SEK 500 million a year at full production in 2021. However, Anders Nyström said: “Ramp up of the new contracts is taking longer than previously announced but is expected gradually to compensate for the general market downturn over coming quarters.”

Hilti reports growth in demanding environment Hilti Group increased sales over the first eight months of the year by 4.2%, to CHF 3.9 billion (€3.54 billion). It also posted significant growth in both operating result (+11.1%) and net income (+11.2%).

hristoph Loos, Hilti CEO, commented: “Due to political tensions at both the international and local levels the economic climate has not grown any easier. Overall, the market dynamics have eased somewhat, which can be seen in the slight reduction of our growth rates.” Sales in local currencies increased 6.4% over the eight months but renewed weakness in the euro, and a devalued British pound, exacerbated the negative currency effect to the Swiss franc. Europe and North America regions both increased sales in local currencies by 7.1%. Latin America also posted strong growth, at 9.4%, with the recovery in Brazil making a significant contribution. The Asia–Pacific region achieved growth of 4.7%, negatively influenced by difficult environments in Hong Kong and Korea. The situation in the eastern Europe/Middle East/Africa region (+2.8%) was mixed with Russia and the eastern European markets contributing to growth – while business in the Gulf States and in Turkey remained difficult due to ongoing political uncertainties. Despite increasingly negative currency influences and continuing investments, the Group’s operating result was 11.1% (CHF 506 million) while net income also grew by 11.2% (CHF 365 million). This resulted in solid levels for both return on sales (12.9%) and return on capital employed (21.6%). Against the background of local challenges in certain countries and international trade disputes, Hilti Group anticipates an increasingly volatile economic environment. For the full year the company expects growth rates in both sales and profitability to be in the mid-single-digit range.

FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

THINK BIG

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INDUSTRY NEWS

Anixter agrees private equity acquisition Anixter International Inc has agreed to be acquired by an affiliate of private equity firm Clayton, Dubilier & Rice LLC (CD&R) in an all cash transaction valued at US$3.8 billion (€3.4 billion). The transaction will take Anixter private and is expected to close by the end of first quarter 2020.

nder the merger agreement terms, CD&R managed funds will acquire all outstanding shares of Anixter common stock for US$81 per share in cash, representing a 13% premium over Anixter’s closing price on 29th October 2019, and a premium of around 27% over the 90 day volume-weighted average price up to that date. “We believe this transaction is in the best interest of Anixter and our stockholders,” said Bill Galvin, Anixter’s president and chief executive officer. “After careful and thorough analysis, together with our independent advisors, our board of directors unanimously approved this transaction with CD&R, which has a strong reputation and a track record of success in helping industrial distributors, like Anixter, prosper and grow. We are also pleased that this transaction appropriately recognises the value of Anixter’s customer relationships, technology and solutions, financial management and global market position. It’s a great outcome for Anixter’s employees, customers and partners. As a private company, we believe Anixter will have greater flexibility to focus on and accelerate our long-term strategic priorities.” Nate Sleeper, partner at CD&R, said: “Anixter is an exceptionally well positioned industrial distributor with leading market positions and differentiated capabilities that deliver strong customer value.

We look forward to partnering with the outstanding management team, led by Bill Galvin, on initiatives to grow the business and further strengthen its competitive position – while maintaining Anixter’s distinctive culture grounded in operational excellence, innovation, and an unwavering commitment to the company’s employees, customers, and global partners.” Bill Galvin, and other members of the current executive management team, are expected to continue to lead the company. Anixter’s board of directors has unanimously approved the agreement and recommends Anixter stockholders also approve it. Certain stockholders, including entities associated with Sam Zell, chairman of the Anixter board, which own approximately 9% of the outstanding shares of Anixter common stock, have agreed to vote their shares in favour of the merger. The transaction is subject to the approval of Anixter’s stockholders, regulatory approvals and other customary closing conditions.

LISI Aerospace growth offsets continued automotive challenges LISI Group reported consolidated sales of €1.3 billion for the first nine months of 2019 – an increase of +6.3% compared with the same period in 2018. At constant scope and exchange rates, sales increased +3.9%.

hird quarter consolidated sales were €412 million, up +6.7% on the same quarter in 2018 but down -6.6% quarter-on-quarter. The Group confirmed positive organic growth since the beginning of the year driven, by its aerospace and medical divisions. On a like for like and CER basis, LISI Automotive, which contributes 35% of Group sales, returned marginally to organic growth (+0.6%) in the third quarter, but the year to date cumulative position remained negative (-4%). The net effect of acquiring Hi-Vol Products Inc in North America (October 2018) and disposing of Beteo in Germany (December 2018) was €25.5 million additional sales up to September 2019. Net sales for the ninth months were €448.3 million (2018: €437.1 million). LISI reckons global automotive sales declined -5.6% in the first nine months of 2019. China declined -10.3%; Europe did better at -1.6%. However, Quarter 3 2018 was a low base for the European automotive industry because of the introduction of WLTP environmental standards. By contrast, LISI Aerospace (57% of Group sales) reported +9.3% organic growth in the third quarter, and +8.5% cumulative (like for like and CER). Nine month net sales were €741.8 million (2018 same period: €687.1 million). Growth reflected accelerated demand for fasteners from the European aerospace sector as single aisle production recovered. LISI also saw “good momentum” in North America, despite lower demand from the Boeing 737-Max programme, which is expected to negatively impact LISI sales by €15 million – €20 million during 2019. LISI expects this, and the disposal of Indraero-Siren and Crueset Morroco in July, to be offset by sustained activity in aero engines, business jets, defence and helicopters. LISI says long-term prospects for the global aerospace market remain strong.

FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

PINSTRUCTURE LTD Tel: +44 1527 67999 Fax +44 1527 66557 email sales@pinstructure.com

www.pinstructure.com 50 EnďŹ eld Industrial Estate, Redditch, Worcestershire B97 6DE

INDUSTRY NEWS

Change in the Hilti executive board Jörg Kampmeyer, a member of the Hilti executive board since 2011, will leave Hilti at the end of the year to take over the position of general partner of Gebr Knauf KG, one of the worldwide largest building material suppliers – headquartered in Iphofen, Germany. He will be succeeded as of 1st January 2020 by Avraham (Avi) Kahn, currently head of the region North America.

örg Kampmeyer started his career at Hilti in 2002 at the headquarters in Liechtenstein. In 2006 he was promoted to general manager in Germany and took on the additional responsibility as region head of central Europe in 2010. Under his leadership, the region achieved strong growth and played an important role in the development of its international sales and marketing standards. In April 2011, he was appointed to the executive board with responsibility for finance, human resources, IT and corporate development. Since 2017, in addition to his responsibility as CFO, he has also been responsible for strategic marketing and the regions in Europe. Avi Kahn began his Hilti career in sales in the USA in 2004. After holding various management positions, he was promoted to general manager for Hilti Canada in 2011. In 2017, he took over the

responsibility for the entire North American region and became a member of Hilti’s executive management team. With this change, Hilti will have two new executive board members for the global sales regions as of 1 st January 2020: Joaquim Sardà (as already announced in July 2019) with responsibility for Europe and the Middle East, and Avi Kahn for the Americas and Asia regions. Executive Board Member Matthias Gillner will take over responsibility for finance and tax from Jörg Kampmeyer. CEO Christoph Loos commented: “With his high-level of energy and commitment, Jörg Kampmeyer has substantially influenced the development of finance, marketing, sales and digital at Hilti. We very much regret his departure but are also happy about his new and exciting role. We thank him for his strong contribution to the development of the Hilti Group over the past 18 years and wish him success and all the best for his next steps.”

CEO leaves Optimas suddenly

Nedschroef Beckingen celebrates 150 years of success

Optimas OE Solutions LLC has announced that Chief Executive Officer Anesa Chaibi decided to leave the company on 18th October for personal reasons.

Nedschroef Beckingen, an affiliate of the leading Dutch automotive supplier Nedschroef, celebrated its 150th anniversary in September. Founded in 1869 as a factory for small hardware in Beckingen, Nedschroef Beckingen is now a recognised manufacturer of fasteners.

he company statement notes that Anesa Chaibi had led significant change throughout the company since her appointment in 2014. With immediate effect T.J. Rosengarth, who joined Optimas’ owner American Industrial Partners as a partner this year, stepped into the Optimas CEO role. From 2011 to 2018, he was CEO of Northwest Hardwoods, a global provider of hardwood products. Prior to this, he ran Weyerhaeuser’s Composite Panels business – with operations in Ireland, France, and North America – from 2001 to 2006, and carved out the Composite Panels business from Weyerhaeuser and ran the standalone US business for Flakeboard from 2006 to 2011. The company statement concludes: “With a solid board, strong senior management team and exceptional financial backing, Optimas continues to be well positioned for future growth. We remain committed to our customers, our suppliers and the communities we serve.”

örg Bosch and Stefan Tils share the management of Nedschroef Beckingen. “We are proud and grateful that our Beckingen plant has successfully overcome the company’s challenges and that we can celebrate this anniversary,” said Jörg Bosch. Stefan Tils added: “We’ve been able to invest a lot in the plant over the past four years, so today we are seeing a relatively stable utilisation of our production again.” Nedschroef Beckingen is the main employer in the local community. A ceremony attended by Saarland Prime Minister Tobias Hans, MerzigWadern County Councillor Daniela Schlegel-Friedrich, and Mayor of Beckingen Thomas Collmann, kicked off the 150th anniversary celebrations. The celebration was entirely dedicated to the employees, their families and visitors to the Beckingen site. There was also an Open Day, so the employees’ families could have the opportunity to take a closer look at the plant during a tour. The event was rounded off with a concert by the Beckingen Wind Orchestra; the Saarbrücken Truck Knowledge Workshop; and an exhibition of the history of the company, about which a commemorative publication will also be produced.

E&O

FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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INDUSTRY NEWS

Nord-Lock Group wins prestigious export award Swedish-based Nord-Lock Group has won the prestigious Export Hermes award given by the Swedish Fund for export development. Nord-Lock Group’s CEO, Fredrik Meuller, accepted the award from HRH Prince Daniel during the Tendency Day – held at the Musikaliska Concert Hall in Stockholm.

ord-Lock Group, a world leading manufacturer of safe and reliable bolt securing solutions for advanced applications, won the Export Hermes award for its wedge-locking washer – a product that is a global leader for its ability to secure bolted joints that are exposed to severe vibration and dynamic loads. It is used worldwide in everything from wind turbines, Shinkansen trains and NASA satellites to semiconductor fabrication plants. The Export Hermes award has been presented each year since 1981 to Swedish companies that have achieved exceptional export success, thereby contributing to Sweden’s prosperity. The jury’s reason for giving this year’s award to Nord-Lock Group was: “Nord-Lock Group has an impeccable business history of leveraging its wide ranging engineering expertise and product innovations to become a global export company that actively supports the foundations of modern society.”

New CEO of Lesjöfors Ola Tengroth has now been appointed as the company’s new CEO, taking over from KjellArne Lindbäck, who will be retiring at the end of the year.

la Tengroth will assume his new position on 1 st January 2020. He most recently served as CEO and joint owner of Kemetyl AB. Prior to that, he worked at industrial companies such as Univar, BASF and SKF, and held various senior positions over a period of 25 years. Lesjöfors, subsidiary to Beijer Alma, has revenues of SEK 2.625 billion (€245.6 million) and operating profit of SEK 531 million for 2018. Under Kjell-Arne Lindbäck’s leadership, Lesjöfors developed into a strong, profitable business, with 1,700 employees in 15 countries. Today, the company is the largest aftermarket/chassis springs player in Europe and one of few global manufacturers of customised industrial springs, wire and flat strip components. “On behalf of the board of directors and all of our employees, I would like to thank Kjell-Arne for his outstanding contribution over the years,” says Henrik Perbeck, president and CEO at Beijer Alma. “At the same time, we are proud to welcome Ola Tengroth to Lesjöfors. The company will continue its journey of international growth, through both acquisitions and organic development. Ola is the right person to lead this work. He has extensive, international leadership experience from various industrial settings, as well as the customer centric business expertise needed to further develop Lesjöfors Group.” Ola Tengroth commented: “I am joining a reputable, well managed company, with a clear agenda for its ongoing development. I look forward to contributing to Lesjöfors’ continued success in the coming years, together with the company’s senior management and employees.”

FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

Nord-Lock is the unlikely story of how an innovation from a bankrupt Canadian company was purchased by a small company from Mattmar in the mid-Sweden county of Jämtland. The company spent many years battling to get the product to market, with the first pair of wedge-locking washers being manufactured in 1982 in a barn in Mattmar. Twelve years later, Nord-Lock Group was acquired by listed investment company Latour and it has grown into a world leading company with global production. “Nord-Lock Group has firmly built up a world leading business, with many big name companies on its list of global customers. Nord-Lock Group currently has a turnover of SEK 1.4 billion and employs 600 people in 25 countries. Our journey has been fantastic and fortunately we’ve only just scraped the surface up to now,” says Fredrik Meuller. www.nord-lock.com

Sherex opens first European office Sherex Fastening Solutions LLC, a global leader in engineered fasteners, tooling, and automation, has opened its first office in Europe.

herex says the office, located in Burnley, England, responds to the demands of current customers and will help further expand Sherex’s fastening solutions into the European and Middle Eastern markets. “The UK facility will provide design and technical support and be our sales and distribution centre for the UK and Europe, where we will continue to work even more closely with our long-term partner Dejond N.V in Belgium,” said Michael Carbine, managing director at Sherex. “We are thrilled to further expand our global footprint.” In addition to its new UK office, Sherex has four established facilities in North America and Taiwan, including manufacturing capabilities. In 2004, the company had only one office located in western New York. “We’re proud of our growth,” said Adam Pratt, president at Sherex. “By having offices in the UK, United States, and Mexico, and manufacturing in Taiwan and Akron, Ohio, we’re globally positioned to quickly react to our customer requirements for global support.” Sherex Fastening Solutions manufactures fasteners for thin sheet material applications in steel, aluminium, and composite materials. Sherex products include rivet nuts, clinch nuts, inserts for composite, stud and nut plates, and through the acquisition of Disc-Lock®, wedge-locking washers and nuts. Sherex has grown to 200 employees and services a wide range of industries, including automotive, general manufacturing, energy, agricultural, and aerospace.

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INDUSTRY NEWS

New acquisition and management at Bontempi VIBO Italian manufacturer Bontempi VIBO has acquired the entire ownership of FRAM Srl, with the company set to become part of the single organisational structure by the end of 2019.

et-up at the beginning of 2016, FRAM was created to add expertise in hot forged bolt manufacturing to Bontempi Group’s existing wide range of cold forming capabilities. “In nearly 60 years of being active on the market, we have never set a final destination for our growth,” explains Raoul Bontempi, CEO at Bontempi VIBO. “As a business we want to continuously evolve and obtain the highest customer satisfaction levels. By incorporating FRAM within the Bontempi Group we continue to lead the fastener industry for cold forming and hot forging – all under the Bontempi name.” Marco Polato – who founded FRAM alongside Raoul – has also become the new sales manager for the Bontempi Group. This is not the only change to the Group management, Vittoriano Calomeni (pictured right), who was sales manager at Bontempi VIBO for over 15 years, has now become the general manager. “Due to the complexity of managing a company with more than 150 people, divided into 3 production plants, I decided to include in our organisation the new role of general manager – with Vittoriano the ideal choice,” states Raoul. “Looking forward, our goal is to continue to grow Bontempi VIBO and be a leader within the global fastener industry.”

Berardi sets up Moroccan branch Berardi Group has established a new branch in Morocco – Berardi Maroc – as an exclusive distributor of fasteners and C-parts, with the branch still managed directly by the headquarters in Italy.

erardi Group explains: “We aim at serving Moroccan clients the same way as we do in Italy, with a proper warehouse and tailor-made, integrated logistics services. There are many different trade opportunities in Morocco, both the national industrial sectors, and in the Free Zone, populated by European companies, mainly in the automotive field. In both areas, demand is high and growing.” The number of products distributed through the Moroccan warehouse will be the same as in Italy, about 100,000 items in total, and 45,000 always on stock. The same goes for new products in the range, especially industrial components and plastic elements. “We are organising weekly shipments to Morocco, so any item that is not on stock will be readily available on demand from the central warehouse in Castel Guelfo,” points out Berardi. “Morocco specific items will always be available on stock. Our experience with requests and clients gives us a clear and wide vision of the local demand.” Berardi can also add value through its quality management and technical offices in Italy, wich are committed to delivering consistently high-quality products with all certifications, and special items for any application. Plus, the company can provide Kanban and Kanban Up services – integrated logistics solutions conceived to support partners with hassle-free supplies of fasteners, clamps, hydraulic fittings, or any other product. “Thanks to these services, our clients save time, money and resources, as everything is taken care of by one single supplier.” www.gberardi.com

20 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

Archerdale appoints new MD Archerdale Ltd, a UK manufacturer and distributor of fasteners, purlin clips, pressings, turned parts and castings, has appointed Tim Graham to the post of managing director with immediate effect.

he appointment supports Archerdale’s forward planning to develop and enhance both the manufacturing and trading divisions of the company, which in turn will help to take the business forward in an ever changing trading environment. Tim Graham’s experience and expertise will be a major factor to drive the business forward in his new role. “We are very pleased to make this announcement and are confident it will assist in maintaining and enhancing the business going forward,” commented Glyn Brown, group chairman. “The appointment reflects my intention to have less involvement in the day-to-day trading activities of the business, which is why I became the chairman of the board of Archerdale Ltd.” Alongside Tim Graham as managing director, Paul Crosby will continue as financial director and Mike Procter as logistics director. Archerdale Holdings Ltd remains the overall owner of Archerdale Ltd and the Group board structure and shareholders remain unchanged.

INDUSTRY NEWS

Hexstone announces ISO 14001 certification Hexstone, the UK’s largest supplier in the fastener and fixing market, has been awarded ISO 14001:2015 accreditation for its environmental management system.

he accreditation joins the Group’s current ISO 9001:2015 quality management credentials and covers all trading divisions: Owlett-Jaton, Stainless Threaded Fasteners (STF), Icon Fasteners and Righton Fasteners. The ISO 14001 environmental management system will continually monitor and improve Hexstone’s environmental performance, from sourcing to supply, in order to ensure best industrial practice and compliance with all relevant legislation. Ian Doherty, Hexstone’s CEO, comments: “We are delighted to be awarded the ISO 14001 accreditation, which is recognised not just in the UK, but in the EU, and across the world. We are also the first and only wholesaler in our industry in the UK to achieve this status. Our teams have worked very hard in order to receive this accreditation.” Ian continues: “We recognised at an early stage the advantages of certification. We live in a global society, which is increasingly concerned with the environmental impact caused by industry, and ISO 14001 certification demonstrates that we take this seriously, and actively want to improve. This gives our customers peace of mind that we go above and beyond with regards to sourcing and supplying responsibly.” “Many companies/manufacturers now require their supply chain to have specific environmental management plans; achieving the 14001 accreditation enables us to demonstrate to our customers Hexstone’s commitment to

reducing its environmental impact. It shows our customers that we are a responsible company, which increases credibility, and helps towards winning new customers.” Reducing waste and energy is primarily beneficial to the environment, but will also provide additional benefits to Hexstone in improved efficiencies and reduced operational costs. In just the last twelve months Hexstone has: Removed over 15,000 single use plastic bags a year, which would have previously gone to landfill. Seen an uptake in customers reusing its packaging, through increasing the gauge of the cardboard used for sending goods out, thus extending the use, and saving on production energy. Reduced its landfill waste figure down to just 0.08%. Moved away from conventional vinyl tape; this means that 90% of card waste is now recyclable and 590,000m of plastic tape is now being replaced with paper tape. Ensured that all fillers and packers used in their packaging are 100% recyclable. Ensured all pallet/wood and metal waste is recycled. Recently converted to LED lighting – saving over 240 tonnes of CO2 a year. Promoted hybrid vehicles for company car users and installed energy efficient electric car chargers. Ensured all waste electrical items are donated to charity for component recycling. www.hexstone.co.uk

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PERSPECTIVE by Phil Matten, executive editor, Fastener + Fixing Magazine

Phil Matten reflects on some of the key topics currently involving the fastener industry The European Automobile Manufacturers Association (ACEA) recently published its report on ‘Making the Transition to Zero-Emission Mobility’1 .

can our News pages and you’ll find plenty of evidence that the fastener supply chain to the automotive sector has been having a torrid time. A six week strike by General Motors workers at plants across the United States hasn’t helped. European car registrations for the first nine months of 2019 were down 1.6% year-on-year. For China the decline was more than 10%. The Detroit ‘big three’ are not issuing monthly figures so it’s harder to gauge the picture in the United States, but from available statistics times are certainly challenging. The ACEA report focuses on Europe where new EU CO 2 emission standards for light vehicles come into effect between 2025 and 2030. Presently, the market penetration of electric and other alternatively powered vehicles remains ‘low and fragmented’. The ACEA finds that only in four EU countries is the market share (of new 2018 sales) of electrically chargeable vehicles (ECV) greater than 2.5% and half of EU states have an ECV market share of less than 1%. Overall in 2018, 56.7% of cars sold were petrol powered, 35.9% were diesel, down from 44% in 2017. In Q2 2019, that petrol share was 59.5% and diesel 31.3%. Of cars actually on the road in 2018, 0.2% were ECVs, 0.6% hybrid electric. Unsurprisingly, ACEA found a direct correlation between a country’s GDP per capita and the uptake of ECVs – with 80% of sales concentrated in six countries. Purchase incentives for ECVs differ greatly, with only 12 countries actively incentivising conversion to AFVs. The most telling statistic, however, is that, by the end of 2018, there were 144,000 charging points across the EU – many not actually suited for fast charging. That’s 317% more than in 2014 but 76% are in four countries covering little more than a quarter of the EU total surface area. Now, for the really sobering number. Based on European Commission estimates at least 2.8 million ECV charging points will

be required by 2030 – a 20 fold increase in twelve years. Just a few days ago Chancellor Merkel said Germany should aim to install a million charging points by 2030 – currently it has 20,000 public points. There are other challenges – ratcheting up battery batteries, achieving realistic ECV range at affordable prices, and finding ways to generate the required electrical supply sustainably. Climate activists argue we need to apply ‘cathedral’ thinking to resolve climate and environmental change – adopting the model of our medieval ancestors who came together over decades to create these magnificent structures. They have a point. We also need to do something far simpler – one would think anyway – which is to get to grip with the real numbers. In these times of hyper-rotational soundbites and downright inaccurate assertions in the pursuit of short-term gain, it’s refreshing to read a report that uses solid numbers to inform decisions. Vain hope in the run up to a UK general election I fear… but politicians, please take note. ¹ht t ps : // w w w.acea .b e /publ icat ion s/a r t ic le / making-the-transition-to -zero -emissionmobility-2019-progress-report

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NORTH AMERICAN NEWS by John Wolz, editor, GlobalFastenerNews.com

North American FINdex growth slows in Q3

After climbing 13% in the second quarter, the FIN Fastener Stock Index slowed to a 5.4% growth in the third quarter of 2019, lower than the 6.8% gained by an index of related industrial stocks.

or the second consecutive quarter, Arconic achieved the largest percentage gain of the period, rising 54.2% in the third quarter of 2019. The company plans to separate its portfolio businesses by Q4 2019, a move praised by analysts. The current EP&S (engine components, fastening systems, and engineered structures) and forged aluminum wheels businesses will be named Howmet Aerospace. Global Rolled Products and Construction Systems will operate in a company that retains the Arconic name. Other FINdex companies with gains of 10% or more during Q3 included Carpenter Technology Corporation (up 45%); bisco Industries Inc (up 52.5%); ITW (up 23.5%); Lawson Products (up 22.5%); Simpson Mfg Company (up 28.2%); Stanley Black & Decker (up 20.6%); TriMas Corp (up 12.3%); and Wesco Aircraft (up 39.3%). In the first nine months of 2019, the FINdex gained 19.8%, lower than the 23.2% increase by an index of related industrial stocks. The FINdex contracted in 2018, hampered by volatility that dominated the markets, making 2018 the worst year for stocks in a decade. The FINdex declined 7.1% during the year, compared to a 7% drop by an index of related industrial stocks. The loss followed two consecutive years of double-digit growth.

US Department of Commerce finds dumping of Asian threaded rod The US Department of Commerce announced affirmative preliminary determinations in the anti-dumping duty investigations of imports of carbon and alloy steel threaded rod from China, India, and Taiwan.

ommerce found that exporters from China, India, and Taiwan dumped carbon and alloy steel threaded rod at the following rates: China: 4.81% to 59.45% India: 2.04% Taiwan: 32.26%

Commerce will accordingly instruct US Customs and Border Protection to collect cash deposits from importers. In 2018, the value of carbon and alloy steel threaded rod imports from China was US$325 million; India was US$111 million; and Taiwan was US$156 million, according to the American Journal of Transportation. The petitioner in this case is Vulcan Threaded Products (Pelham, AL). Since the beginning of the current administration, Commerce has initiated 182 new anti-dumping and countervailing duty

28 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

investigations â&#x20AC;&#x201C; a 231% increase from the comparable period in the previous administration. Commerce currently maintains 496 anti-dumping and countervailing duty orders. Commerce is scheduled to announce the final determination with respect to Taiwan by 4th December 2019, and with respect to China and India by 11th February 2020. If Commerce affirms its determinations, the US International Trade Commission (ITC) will be scheduled to make its final injury determination with respect to Taiwan by 24th January 2020, and with respect to China and India by 26th March 2020. If Commerce makes affirmative final determinations of dumping, and the ITC makes affirmative final injury determinations, Commerce will issue anti-dumping orders. If it makes negative final determinations of dumping, or the ITC makes negative final determinations of injury, the investigations will be terminated and no orders will be issued.

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NORTH AMERICAN NEWS

Agrati completes US$4 million upgrade Agrati Group completed a US$4 million investment in industrial machinery and equipment at its facility in Tiffin, OH, according to a press release from the Tiffin-Seneca Economic Partnership.

grati worked with National Machinery to purchase a new FORMAX cold former this year to expand capacity. The company also worked with Arnold Machine Inc of Tiffin to purchase custom assembly machinery. “Agrati is very committed to its operations in Tiffin and plans to continue to grow and invest here in the coming years,” stated Casey Poignon, plant manager. In 2018, Agrati invested US$1.6 million in industrial machinery, equipment and renovations to its facility, in addition to adding ten jobs, according to the Tiffin-Seneca Economic Partnership. The company produced more than 177,355,326 fasteners and shipped 10,001 orders to Fiat Chrysler Automobiles, General Motors, and other global customers. Agrati said it is considering additional investment at the plant next year. It currently employs 66 people, having been expanded in 2013 with the addition of a 40,000 square feet building. The Tiffin plant, previously Jacobson Manufacturing, was acquired by Agrati in 2016 as part of the deal to acquire ContMid Holdings Inc (CMG) from equity firm Monomoy Capital Partners for an undisclosed amount.

Park Forest, IL-based CMG is a US$240 million manufacturer of custom engineered metal fasteners, cold formed parts and stampings for car makers, automotive suppliers, and industrial manufacturers. CMG markets its products, which include safety critical seat belt fasteners, automobile door strikers and wheel nuts, under the trade names Continental/Midland, Jacobson, Tiffin, MSD Stamping and Minuteman Distribution. It also provides Taptite® and TORX® products and wheel nuts throughout North America. The Tiffin plant is one of twelve Agrati production facilities worldwide, including two in Ohio. It focuses on cold forming, tapping and thread rolling auto and truck wheel nuts, as well as tubular products and highly engineered safety restraint components – produced through automated welding and assembly. Founded in 1939, Agrati is a privately owned multinational manufacturer of fasteners and assembly components for the automotive and general industrial markets. It employs more than 2,600 workers and acquires about 160,000 tonnes of steel annually to manufacturer about 8 billion pieces.

3D printing becoming “handful of dollars, overnight and in-house” When a manufacturer needed a guide for a nail gun it used to mean outsourcing to a specialised shop. “That is expensive,” 3D Engineer Andrew Edman told a 2019 International Fastener Expo conference. But with 3D printing it can be “a handful of dollars, overnight and in-house”.

astener prototypes, testing, shape, and tightening tolerances, are among current uses, Edman told IFE. 3D printing can be used for custom riveting, inspection and a system for feeding in parts alignment. Edman, industry manager for product design, engineering and manufacturing at 3D printer company Formlabs, recalled using a 3D printed fixture at Ashley Home Furniture that weighs much less and is faster to change over compared to their traditional machined fixture. He also cited use of a 3D printer for a mould to form a silicone part at Reynolds Advanced Materials. In the 1980s 3D printers “weren’t robust enough”, Edman acknowledged. As they grew, they became “big US$100,000 machines”. Today 3D has become “low risk” making entrepreneurs “free to experiment”. For example, New Balance shoes uses 3D printers for a section of the midsole. But that is just a beginning, Edman predicted. In the shoe industry, Edman said 3D printing “will go further and make customized shoes. You will stand on a scale, which will generate a shoe built for you”.

30 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

Today 3D printing at the end of a product allows customising without tooling costs – such as Gillette putting individual names on razors. But the customization is more than cosmetic – such as at dental labs or in hospitals, Edman said. With 3D customisations, “you don’t have to live with ‘good enough’”, he added. Manufacturers can reduce costly slowdowns and control the supply chain with 3D printing. Metal printers thus far are more expensive, “but will become more available”, Edman predicted. 3D is growing “parallel to robotics”, he concluded.

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NORTH AMERICAN NEWS

JV to produce highly corrosion resistant fasteners

Metal and alloys manufacturing start-up, Modumetal Inc, is partnering with Toyota Tsusho America Inc, Toyota’s trading arm, to open a 20,000 square foot production facility in Houston, the Houston Chronicle reports.

he joint venture will make specialised alloy products for the oil and gas industry, with capacity to produce more than 100 tonnes of materials monthly. Seattle-based Modumetal makes nano-laminated metal products manufactured with layered metals using electricity rather than heat, producing products stronger than conventional steel and able to resist corrosion at high temperatures. “Modumetal founder and CEO Christina Lomasney said the companies chose Houston for its access to oil and gas companies, their primary customer base, since these companies need various

Agrisolutions to acquire Carl Sülberg Agrisolutions has agreed to acquire German-based Carl Sülberg GmbH, a manufacturer of forged steel guards for harvesting crops, North American sales VP Dan Zehnder announced.

om Welke, president at Agrisolutions, stated: “Sülberg is a very reputed company in the sector with a high-quality product, on time delivery and continual development of new products in the harvesting sector. This new company will, for sure, increase our product offering to the leading OE’s demanding a global range of products.” “There is still more to come as we are building a new unit/division that will be expanding our fastener capabilities and offerings as well,” Zehnder added. In July, Agrisolutions agreed to acquire U.S. Mfg Inc (USM) for an undisclosed sum. Eldora, IA-based USM manufactures hammer mill components for OEM and MRO markets. The company is led by CEO Loran Balvanz. Agrisolutions also acquired fastener supplier Trinity Logistics Corp in March 2018. Trinity was founded in 2003 by former NFDA vice-president Dan Zehnder, who was named VP of North American sales for Agrisolutions.

metal fastening and bolting that can withstand high amounts of stress and exposure to corrosion (think deep sea offshore rig parts),” writes Erin Douglas of the Chronicle. While Modumetal has partnerships with Chevron and ConocoPhillips, the company anticipates selling products to construction and transportation industries. “With several recent corrosion related automotive recalls over the past 12 months, our NanoGalv® coatings are enabling a breakthrough in safety at a critical time for the market,” Lomasney told the Chronicle.

ITW Q3 automotive and construction sales decline ITW reported Q3 Automotive OEM revenue, which includes fasteners, down 4.7% to US$744 million (€667 million). Construction Products revenue declined 3.6% in the quarter to US$416 million.

utomotive OEM organic growth in the third quarter declined 2.3% (4% on an equal days basis). North America recorded a -6% fall in organic growth, with -1% attributable to the General Motors strike. European organic growth was flat and China recorded 7% growth. Automotive OEM operating margin improved 60 basis to 22.1%. For the first nine months of 2019, Automotive OEM revenue fell 8.7% to US$2.338 billion, including a 5.4% organic sales decline. Operating margin was 21.6%. Construction Products third quarter organic growth was 1%, with North America flat and Europe at 15. Operating margin was down 70 basis points to 25.1%. Nine-month Construction Products revenue fell 4.8% to US$1.241 billion. ITW consolidated sales fell 3.7% to US$3.479 billion in the third quarter, due to organic sales falling 1.7% and negative currency effects. Nine-month consolidated revenue fell 4.9% to US$10.64 billion. Operating income fell 5.3% to US$2.46 billion.

Stanley Engineered Fastening sales decline in Q3 Stanley Black & Decker Engineered Fastening revenues were down 4% in the third quarter of 2019, as gains in market share were offset by inventory reductions and lower production levels within automotive and industrial customers.

ngineered Fastening revenue for the third quarter 2019 was US$429.5 million (Q3 2018: US$451.2 million). Nine months’ revenue to September was down 1.9% year-on-year at US$1.306 billion (9 months 2018: US$1.331 billion). Sales for the Industrial segment, within which Engineered Fastenings reports, increased 12.6% against Q3 2018, primarily reflecting the acquisition of IES Attachments in March 2019 (+16%), offset by a volume decrease (-2%) and negative currency effect (-1%). The fall in engineered fastening volume, together with externally driven cost inflation, pulled the segment’s profit rate from 16.8% in Q3 2018 to 15% Q3 2019. Nine-month 2019 net sales for the Industrial Segment were US$1.838 billion, 12.1% up on the same period in 2018 at US$1.639 billion. Tools & Storage net sales in Q3 2019 were US$2.534 billion, a 3.51% increase over the same quarter in 2018, with volume and price improvement partially offset by currency. Organic growth for the quarter was led by North America (+7%) and Europe (+4%) mainly driven by new product launches. Emerging markets recorded a -1% decline in organic growth.

32 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

RUSSIAN + CIS NEWS Alexander Ostashov, editor, Fastener, Adhesives, Tools and…Magazine www.fastinfo.ru

All-Russian Conference Wire – Fasteners 2019

On 25th September 2019 representatives of leading hardware companies met at the 8th All-Russian Conference Wire – Fasteners 2019 in Moscow.

he participants gave their assessment of the general market situation and examined its influence on the hardware industry. They talked about the immediate prospects for the development of their products. The conference highlighted many issues needing consideration by hardware manufacturers. Question 1 on the list of ‘systemic’ questions, presented by the general director of the Prommetiz Association, Boris Yarantzev, was the protection of the domestic market. There was a pessimistic attitude amongst participants because many were focused on the currently unfavourable situation for business development in Russia. As Mr Yarantsev said: “The only thing that helps to increase sales is the activity of the trading companies. Consumers and traders are currently conservative in their ambitions; their activity for the development of sales level is zero or negative. It is

Rechitza Hardware plant increases nail supply to Europe Vitaly Belsky, head of the department of foreign economic relations at the Rechitza Hardware plant in Belarus spoke at the All-Russian Conference Wire – Fasteners 2019, reporting increasing sales to non CIS countries and fall in those to Russia.

e said that 42% of the plant’s nail sales were now to non CIS countries, with 34% going to Russia and slightly more than 23% being supplied to domestic Belarusian consumers. This trend is associated with more attractive prices in the European market, which correlate with raw material prices. Mr Belsky said the current situation is based on an increase in protectionism, redistributing forces in the market, while the toughening of norms and standards increases the cost of production. Vitaliy Belsky also noted that the Rechitza Hardware Plant is improving its fasteners range, and he presented examples of new products to the Conference. He added that, before the end of the year, the Rechitza Hardware plant will launch a number of new products on the market.

only a national strategic development project running though to 2024 that can play the role of the main driver to overcome stagnation.” Another speaker, Marina Kholopova from OJSC MMK-METIZ, proposed one possible direction of development – an increase in production for export sales. Several reports were also devoted to issues relating to fastener production. Ilya Belyakov, head of analytics at NLMK-Sort LLC, spoke about the prospects for import substitution of fasteners. Alexey Sorokin, general director of BelZAN MET LLC, made a presentation on the modern requirements for metal for fasteners and springs in mechanical engineering. Yuri Lavrinenko, head of the department of FSUE NAMI, presented on ‘Development of fastening joints for the automotive industry’. The topic of fasteners was also mentioned in other reports, including those related to standardisation.

Orlovsky plant trials fasteners from weatherproof steel

Metal Supply and Sales Magazine reported that the Orlovsky steel rolling plant (part of Severstal-Metiz) manufactured an experimental batch of fasteners from an innovative weather resistant steel grade.

ccording to the report, Severstal has been producing this grade of steel at the Cherepovetz steel mill. It has already been tested in the manufacture of metal structures by Severstal Steel Solutions. Now, the Orlovsky steel rolling plant has mastered the production of weatherproof steel fasteners of the Cherepotz steel mill. Currently these are bolts of three strength classes and rivets. In the future, the plant plans to master the production of nuts and expand the range of bolts. In the spring of this year, the BERVEL high strength fastener plant presented Russian-made weatherproof steel bolts at the Fastener Fair Stuttgart exhibition.

Fastener producer ‘business club’ meets in St. Petersburg On 19th September, the first meeting of the informal business club of fastener producers took place at the Vedensky Hotel, located on the Petrograd side – the historical district of St. Petersburg.

he topic ‘Strategic planning in the fastener business’ was discussed in a round table format. The leader of the fastener producers’ business club is Nikolai Prokhorov, vice-president of the Alfa Ars Group of companies (Moscow). Participants showed great interest in Alda Ars Group experiences in developing and implementing strategies for its fastener business. Another interesting topic discussed at the meeting, was the experiences of some St. Petersburg companies, which are developing steadily in the current difficult economic conditions.

34 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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ASIAN NEWS

Chin Well profits hit in final quarter Chin Well Holdings reported a stagnant final quarter (ending 30th June 2019), with profits shrinking more than 35% year-on-year. However, sales continued to grow, with revenues up 10.8% year-on-year.

hin Well’s fastener business reported final quarter sales increased 10.75% to MYR 126.88 million but pre-tax profit was down 20.7% to MYR 15.26 million. The company says this reflected an adverse product mix effect. The Group’s metal wire business saw sales increase 11% in the final quarter, to MYR 39.34 million. Chin Well launched a new production line in April, and high costs impacted profits, resulting in a MYR 250,000 loss before tax.

Chin Well has benefited from the US-China trade war with sales to American customers continuing to increase in the final quarter. Full year exports to North America more than tripled (363%) to MYR 72 million. Fastener World Magazine says, the undermined quarterly performance was not triggered by structural factors, which means the current weakness is temporary, with company fundamentals unharmed and profits expected to recover. MYR 1,000 is around €218 at Interbank

Boltun to open two new plants in Taiwan Boltun Corporation plans to establish two new production facilities in the Rende and Yongkang districts of Tainan, Taiwan.

verall investment in the new projects is around TW$1 billion (approximately US$33 million). Founded in 1988 Boltun is a highly diversified fastener manufacturer employing around 3,800 people across 21 facilities in five countries, including Germany. As well as being the world’s largest producer of weld nuts, the Group manufactures a wide range of fasteners and parts for automotive and vehicle assembly, accounting for more than 80% of output, and for wind and solar energy projects. Boltun generates annual sales of more than US$600 million.

Taiwan fastener exports decline

In the first half of 2019, Taiwan exported 8.03 million tonnes of fasteners to the world, down 3.18% from the same period last year, according to a report from Chinafastener.info.

he average price per kilogram increased by 0.73% to US$2.89. In June, Taiwan’s fastener export dropped by 0.131 million tonnes, down 6.11% from the same period last year and down 4.18% from May. The average export price in June was US$2.94/kg, up 2.14% from the same period last year and up 2.17% from May. In 2018 Taiwan exported 1.68 million tonnes of fasteners, an increase of +5.25% over 2017, with an average export price of US$2.884/kg. The report expects Taiwan’s annual fastener export in 2019 to show a decline in volume.

Potential improvement in Taiwan fastener exports in 2020 TIFI says Taiwan fastener exports have been in a continuous decline since the end of 2018 and the industry may not see a turnaround until well into 2020.

u-Chin Tsai, chairman of the Taiwan Industrial Fasteners Institute (TIFI), told Fastener World Magazine that fastener exports from Taiwan have been in continuous decline since the end of 2018 and the industry may not see “good conditions” until the second quarter of 2020. Mr Tsai cited the influence of the US-China trade war, explaining that Taiwanese fastener exporters faced heavy price competition from Chinese fastener manufacturers. Following the implementation of US Section 301 tariffs on fasteners from China, US fastener orders previously placed with producers in that country had switched to Vietnam and Malaysia to take advantage of lower material prices and exchange rates. Mr Tsai emphasised that Taiwan fastener manufacturers have superior technology, quality and lead times, but said they cannot compete on price. He welcomed the announcement from Taiwan’s China Steel Corporation to maintain domestic prices for wire rod and hot/cold rolled products unchanged for the fourth quarter 2019. Fastener World had previously reported growth in fastener exports to the US in the first four months of 2019, with a total 236,377 tonnes reflecting a year-on-year increase of 10.2%. In 2018 Taiwan exported 698,155 tonnes of fasteners to the US, up 7.12% year-on-year. The exports were worth US$1.92 billion, up 15.36% year-on-year and representing a new record.

36 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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ASIAN NEWS

Chun Yu sales down in August Influenced by the US-China trade war, the consolidated revenue of Chun Yu was down -8.1% in August, to TW$791 million (€23.3 million), Fastener World Magazine reports.

owever, the report notes, the recent return of some Taiwanese investors to Taiwan to set-up new factories has boosted demand for construction fasteners. As a result, Chun Yu domestic sales increased by 8% month-on-month in August, and were 38% up on the same period in 2018. Chun Yu’s cumulative revenue for the first eight months of 2019 was TW$6.23 billion, a 3.2% reduction on the same period the previous year, says Fastener World reflecting a stable trend.

Taiwan’s JYR Aviation investing in new plant Taiwanese JYR Aviation will invest TW$500 million (€14.7 million) in a new plant, according to Fastener World Magazine.

s one of the top 10 fastener companies in Taiwan, Jau Yeou Industry spun off into the aerospace industry with the founding of JYR Aviation. JYR Aviation is to invest TW$500 million to build a new aerospace technological park in Luzhu District of Kaohisung City, with the objective of gaining new international clients and tapping into the supply chain of large airliners. The investment is expected to create 270 new jobs in Taiwan. The Investment Unit of Ministry of Economic Affairs (Taiwan) said JYR Aviation is the first Taiwanese company to have acquired two aerospace quality grade certificates: AS9120 (for aerospace logistics) and AS9100 (for aerospace manufacturing quality management system). JYR Aviation has been authorised by a global commercial aircraft engine company to provide manufacturing and sales in Asia-Pacific. Fastener World says JYR Aviation has created a new business model for Taiwan’s aerospace industry and has now become an indispensable part in the supply chain for international aerospace sector.

Chun Yu’s sales to China in August increased 9.5% month-on-month. Sales to Indonesia also increased 14.8% and to the United States by 8.1%. According to Chun Yu the Indonesia and US markets will continue to improve but more time is required to evaluate the markets in China and Europe. Chun Yu expects global markets to remain volatile due to the US-China trade war.

Indian automotive production falls 13% The Society of Indian Automotive Manufacturers reports a 13.3% fall in total vehicle production between April and September 2019.

he Indian automotive industry produced a total of 14,427,724 vehicles – including passenger vehicles, commercial vehicles, three wheelers, two wheelers and quadricycle – between April and September 2019 compared to 16,645,330 in April – September 2018, a “de-growth” of -13.32% over the same period last year. During the same period domestic passenger vehicle sales declined -23.56% and sales of commercial vehicles fell -22.95%, compared with the same period last year. Indian automotive exports, however, increased by 1.29% during April – September. Passenger vehicle and two-wheeler sales increased 4.38% and 4.1% respectively. However, commercial vehicles exports declined -41.58% and three wheeler exports fell by -11.59%. Source: SIAM

Drop in demand hits Sundram Fasteners

Standalone revenue for Sundram Fasteners Limited second quarter, ending 30th September 2019, fell -23.2% to INR 766.83 crore. Net profit for the period fell by more than a third.

undram Fasteners says that the drop in industry volumes resulted in domestic sales for the quarter at INR 450 crore, down -28.8% from INR 631.6 crore for the same period in the previous year. Export sales for the second quarter were down -13.1% to INR 291 crore. As a result, EBITDA for the quarter declined -27% to INR 145.4 crore compared with INR 199.4 crore for the same period the previous year. Net standalone profit for the quarter was INR 71.1 crore, -35.8% lower than the INR 110.7 crores for the same period the previous year. The sharp decline in second quarter performance follows a -13% fall in net profit for Sundram’s first quarter ending 30th June. During that quarter, higher export sales only partially offset a -9% drop in domestic revenue. For the half year, standalone revenue was down -13.7% at INR 1,720 crore. Net standalone profit for the half year was down -24.4% year-on-year to INR 164 crore. 1 crore = 10 million INR 1 crore approx €127,000 at interbank

38 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

BRAZILIAN NEWS Sérgio Milatias, editor, Revista do Parafuso, www.revistadoparafuso.com.br

New Metalac ‘president’ Eighteen years after joining Metalac as a fastener engineer, Rodrigo Egêa has been appointed plant manager of Metalac. He is committed to continued expansion of the company’s presence in Brazil, especially in the aerospace sector.

riginally a Brazilian company, Metalac was founded in 1953 in São Paulo City. Between 1957 and 1995 Hungarian Julio Milko and American Léo Braun led the company through an ambitious growth plan, focused on high-tech fastener production. In the 1970s the company moved to a modern factory in Sorocaba, around 120km away. Now, Metalac is a subsidiary of Precision Castparts Corp (PCC), in which fasteners is part of the aeronautical component segment. 2019 has been a special year for Rodrigo Barranqueiro Egêa. The Brazilian engineer joined Metalac in 2001, ambitious to become a fastener specialist, aiming to be the best, but not the president (known in PCC as the plant manager). In 2011, Egêa transferred to

PCC and worked in the USA on development and implementation of several projects, returning recently to Brazil. Egêa came back to a Metalac business already pushing forward on an ambitious innovation process, including diversification and, especially, the implementation of an aerospace fastener production line – something previously unheard in Brazil. In 2018 the company was certified to AS9100, permitting it to produce parts for the aerospace sector. Metalac is one of the most important fastener companies, not just in Brazil but in the whole of South America, with a strong presence in the automotive sector providing critical items. However, this is not enough for Egêa, who believes the potential of the Brazilian PCC unit is just at the beginning.

Brazil automotive sector close to milestone year

Steel production set to decline in 2019

Could Brazil exceed production of four million automotive vehicles in 2019? Achieving this requires continuation of the current production growth of around 2%, but not a fall.

Brazilian crude steel production was -5.4% down until August this year, signalling a full year decline.

n 2018 Brazilian production of Brazilian automotive sector production 2018 - 2019 light vehicles (passenger cars Segments 2018 (Jan/Dec) 2019 (Jan/Aug) and light commercial vehicles) Light vehicles 2,745,739 1,914,690 reached 2,745,739 units. Truck Trucks 105,534 77,046 production was 105,534; buses 28,536; and motorcycles 1,036,88 Buses 28,536 19,379 units. So, total Brazilian production Agricultural and 65,656 36,500 of automotive vehicles ended last road machinery year at 3,916,597. Add to this the Motorcycles 1,036,88 743,556 output of agricultural and offroad Total 3,982,253 2,791,171 machinery at 65,656 units, and the total was 3,982,253 units. From January to August 2019, 1,914,690 passenger cars were produced (year-on-year growth of +2%); 77,046 of trucks (+13.1%); 19,379 of buses (-7%) and 743,556 of motorcycles (+6.6%). That represents overall year-on-year growth of 2%. So, the mark of four million vehicles is close to being achievable. The result will be even better if the mark of three million cars/trucks/buses can be exceeded. Agricultural and off-highway output is currently weak, some 36,500 units (-9.8% year-on-year). Not considering motorcycles and agricultural/off-highway, the last time Brazil closed a year with more than three million automotive vehicles produced was in 2014 (3,146,386). The absolute record occurred in 2013 (3,712,380), while motorcycle production hit its best result in 2008 (2,140,907). Sources: Anfavea (www.anfavea.com.br) Abraciclo (www.abraciclo.com.br)

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espite growth, albeit a little shy, in the metal industrial sector, Brazilian crude steel production was 22.2 million tonnes in the first eight months of 2019, a -5.4% year-on-year decline. Rolled products output was 15.4 million tonnes (-2.5%); and semi-finished products 5.9 million tonnes (-10.7%). Eight month domestic sales were 12.4 million tonnes, representing a -1.5% reduction year-on-year. Domestic apparent consumption of steel products was 13.9 million tonnes until August (-2.3%). Imports for the same period totalled 1.7 million tonnes (-1.1%) with import value down -5.7% to US$1.7 billion (€1.52 billion). Exports reached 8.6 million tonnes, a 1.7% increase, worth US$5.1 billion (-4.8%). Source: Brazil Steel Institute www.acobrasil.org.br

COVER STORY

Guaranteed quality with Ambrovit With market demand primarily focused on product diversification, it is paramount that Ambrovit is ready to meet customers’ needs through a vast stock of quality articles available upon request. That’s why the company continuously adds new products to its catalogue and constantly invests in procedures to guarantee quality.

xpanding its product offering to customers has been a long-term strategy for Ambrovit. Recent additions include rivets and concrete screws, with the latter available with ETA Option 1 certification and with REI 120 fire resistance certification. The anchor screws are also available with Enduro finish for more than 1,000 hours corrosion resistance, making them ideal for use in highly corrosive outdoor atmospheres. When looking at what products to introduce, Ambrovit also pays particular attention to the latest regulations, such as those that impose severe constraints on the use of hazardous substances that are harmful to people and the environment. “We have certainly been a pioneer in this respect. For instance, we began as early as 2017 to adapt our stocks to require all finishes and treatments to be free from hexavalent chromium (Cr6),” mentions Mattia Sozzè, quality manager at Ambrovit. “Quality products are what set us apart from our competitors and this is deeply rooted in every one of our departments. This allows us to offer reliable products and provide a controlled value chain.” In order to maintain its high-quality expectations, and to ensure products are controlled and certified, Ambrovit hand picks its suppliers using a three phase selection process. Phase one – suppliers are evaluated and certified by the purchasing office under the supervision of the head of purchasing. “It is important to us that we know our suppliers personally, in order to be able to evaluate and familiarise ourselves with the quality of the products supplied. We therefore evaluate their suitability and carry out a thorough audit,” mentions Mattia. Phase two involves a request for the product – Ambrovit will send a supplier documentation outlining procedures that must be strictly adhered to. The supplier is then required to carry out inspections and tests and provide reports to guarantee standardisation. Phase three takes place in Ambrovit’s in-house laboratory, which has been equipped with the latest generation of instruments for quality control, and sophisticated software, to guarantee operative reliability. Equipment includes a metallographic micro cutting machine, Rockwell hardness tester, Vickers micro hardness tester and coating thickness tester, as well as a Corrosionbox for salt spray tests according to ISO-DIN. All instruments used are subject to regular calibration tests as stipulated by management procedures to conform to UNI EN ISO 9001:2015 norm. As part of the quality control procedure that applies to incoming products, Ambrovit also carries out various tests in its laboratory in collaboration with the DIBt (Deutsches Institut für Bautechnik and

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CSIC Instituto de Ciencias de la Construcción Eduardo Torroja in Madrid. For the Russian market, the company also possesses GOST-R conformity certification, which testifies to conformity, safety, and other essential requirements. “We are constantly working with our partners to find new products with better services. It’s critical for Ambrovit to make our customers aware of the importance of quality. They can see for themselves the developments we have made and what we’ll continue to make,” comments Mattia. These developments include the introduction of automated storage for incoming goods, which has been operational for just over a year. This has enabled arriving pallets to be quickly added to the system and automatically transported to the automated high bay warehouse – resulting in the flow of products becoming even faster and more efficient. “It is important as a business you

are able to be flexible, so it is easier to follow the needs of the markets and customers. After doubling the size of the automated warehouse in 2016 to 44,000 pallets, we soon realised that whilst we could quickly and efficiently send out orders, there was a bottleneck at incoming goods and getting the pallets into the system. That is why we decided to invest and automate incoming goods, so we could streamline the overall process,” explains Mattia. The high bay warehouse itself is managed by eight stacker cranes. Within the automated warehouse there is a buffer area with 170 positions (equivalent to 5 containers per day), dedicated to incoming goods management, as well as relevant quality control on 3 operating bays. Here the operator, supported by a specialist program, carries out all the necessary inspections against product standards (UNI-DIN-ISO-EN) rather than in accordance with internal specifications and/or client requirements. This new operating system ensures a very high-level of quality and sustainable product standardisation, which Ambrovit states are important market relevant factors. “We also have a miniload warehouse, also fully automated, which manages and handles small loads. This enables us to prepare orders for small quantities, which may involve many articles in a very short space of time. Even in this situation, we can guarantee ultra-fast processing within 24 – 48 hours,” comments Mattia.

To further guarantee the quality of products when arriving at their destination, Ambrovit’s automated system also includes an automatic stretch-hood pallet wrapper to provide proper protection for products during transport. This packaging is waterproof and protects the contents while keeping the integrity of the cartons. “We pay attention to the detail, and that includes putting procedures in place to ensure our products arrive in the correct condition. We’ve invested heavily in our packaging and believe it plays a fundamental role. We therefore want to ensure quality standards in this area,” explains Mattia. Further to this, Ambrovit recently replaced its packaging with customised boxes of various sizes – suitable for any type or length of product. All products are packed in standardised packaging, which enables material to be sorted and received in accordance with its own storage requirements. Moreover, all Ambrovit products are identified by special labels conforming to the standards set down by the regulations currently in force. In addition, its new labels all feature a QR code, enabling technical documentation to be easily downloaded. “Providing this essential documentation easily is an absolute requirement of our industry. The screws, bolts and fastening systems market is expanding all the time and has been growing at a constant rate of approximately 6% since 2010, placing Italy among the world’s leaders in the sector, second only to Germany – we must grow with it,” points out Mattia. “The European market is particularly important to us, and to date we have worked with 54 different countries, but in Europe there is still plenty more scope for action. That is why our constant aim is to expand into new markets, which is why we make sure we have a presence at all the trade fairs and international events for the sector. This means that we are known and able to exhibit all the latest innovations and catalogue products, as well as offer high-quality professional technical support.” “Nevertheless, 2019 has been a period of crisis for many Italian businesses. By diversifying our market and widening our range of products, and their range of use, we have experienced growth and success. In the future we plan to continue along the path we have followed so far, investing in development, quality and all-round support for our clients. We are also putting the finishing touches on a B2B platform to optimise business process management,” concludes Mattia. “We must continue to work with our partners, whilst maintaining our ongoing research into innovation. By underlining the importance of quality we can also inform the customer on the latest regulations and advances that Ambrovit strives towards.” www.ambrovit.it

FASTENERANDFIXING.COM 43

MADE IN GERMANY Deutscher Schraubenverband e.v Dr Stefan Beyer, general manager Dr Beyer has worked within the fastener industry for over 35 years and has been the general manager of Deutscher Schraubenverband (German Fastener Association) since 2010. Editor Will Lowry visited DSV’s headquarters in Hagen, Germany, to find out more about the objectives of the association, as well as the current situation within the German fastener market. What are the main aims of Deutscher Schraubenverband?

“The role of the German Fastener Association (DSV) is to provide technical and commercial support to our members through the use of committees, working groups, workshops, training programmes, and seminars. Our aim is to help our members meet the requirements of their customers. We have 50 full members who are fastener manufacturers and 70 associate members from across the whole of the supply chain – job coaters, machinery and accessories, wire and pre-treatment, test and sorting/process control, torque/tension testing machines, threadlocking and sealing devices, coating systems, power tools, lubrication systems, institutes, tools and tool coatings, as well as others. We have found the associate membership to be particular popular, as it gives companies the opportunity to further understand the fastener requirements of the full members (fastener manufacturers). As an association, we have a very diverse range of member profiles with 48% of members from companies with less that 49 employees; 11% from companies with 50 – 99 employees; 23% have between 100 and 249 employees; and 8% have over 500 employees. A big number of them are family-owned enterprises, a characteristic of our association. As part of DSV there is a professional group for those members focusing on automotive, as well as a group on small screws, rivets, nuts and fasteners for wood applications. These two groups predominately focus on commercial discussions. In addition, we also have technical committees and sub committees that focus on topics such as materials and quality; heading, extrusion, thread forming; health, safety and environment; as well as fastener assembly. Plus, there are working groups for common research and development, surface coating systems, and logistics.

44 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

Since the 1970s we have also regularly had engineers from the Technical University of Darmstadt, who work as research associates within the DSV on their thesis and carry out scientific work on fastener testing, material development, surface coatings, tribology, etc. This helps develop the technical knowledge within the association and these engineers normally go on to work within the fastener industry. The DSV also has a close collaboration with German OEMs through the VDA – Association of the German Automotive OEMs – where we can understand the demands in the automotive industry and invite automotive people into our subcommittees and working groups to discuss issues, solve problems or to launch investigation work or R&D projects. Plus, in 2003 the association helped found the German Cold Forging Group (GFCG) in cooperation with the Steel and Metal Forming Association. Many of the subjects regarding cold forming are the same for both associations, so a partnership made sense. This association is divided into four sub-groups, which focus on tribology, cold forming, material development, and tooling. Finally, the DSV is also connected to the European Industrial Fasteners Institute (EIFI) and is part of the membership that looks at the fastener manufacturing industry across Europe.”

How can the DSV support members and their customers?

“One of our main services is the DSV Fastener Training Academy, where we can offer different training and qualification programmes to members and their customers. The aim of the training academy is to impart fundamental fastener knowledge and create a network between fastener manufacturers and users. Through basic courses and seminars, as well as their own self-study, attendees can take an Initial Examination of

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MADE IN GERMANY Fastener Training, which ensures they have the basic understanding of fastener components and their capabilities. From there, they can then take a further three modules that focus on materials and part testing; construction, calculation and assembly; as well as quality management, along with a lot of practical training. There is then a final written and verbal examination they must take to confirm themselves as a Certified DSV Fastener Engineer or a Certified DSV Fastener Technician. To date, there are over 350 qualified fastener engineers and fastener technicians. For the future, we are also looking to introduce new certifications including Certified Fastener Employee, Certified Fastener Practitioner and Competence in Manufacturing Mechanical Fasteners. These are to coincide with similar certifications within the welding and adhesives sectors. We are able to provide the training academy service thanks to the technical knowledge within the DSV – with the result that our members are able to maintain and improve their competitiveness.”

What is the current situation in the German fastener manufacturing market?

“In 2018 German fastener manufacturers exported 905,000 tonnes at a value of €5.733 billion, which was a sales increase of 4.9% on 2017 (€5.466 billion), but only a production increase of 0.7% (2017: 899,000 tonnes). Regarding the domestic market, 795,000 tonnes were produced in 2018 at a value of €3.877 billion, which was a production increase of 1.1% on 2017 (787,000 tonnes). However, this is still below the 2016 figures when domestic tonnage reached 837,000 tonnes. The number of imported fasteners reached 1,037,000 tonnes in 2018, which is a 5.2% increase on 2017 (986,000 tonnes). As for 2019, so far it has been a challenging year. At the beginning we thought there would be a slowdown during the first half of the year, but it would pick up after the summer holiday. However, now it looks like it will continue for the remainder of 2019. Our membership supplies a lot of different markets and there are different reactions according to these markets. Some companies are experiencing a difficult situation in the automotive market, but there are those that haven’t seen much of a change compared to previous years. A key factor is having other fields to focus on, so you are not dependent on one industry. For instance, construction and

housebuilding is very strong, therefore companies involved in this area are in a good situation and experiencing good growth. Another big factor impacting the markets are the political and economic uncertainties, as well as the situation in the Far East. You just don’t know what is going to happen in the market, which makes it difficult for companies to plan for the future.”

Another service the DSV provides is the monitoring of the cost changes in wire rod. Why and how does it monitor it?

“It is important to point out that in order to conform to the compliance rules, we monitor the cost changes rather than material costs. We collect raw material price changes for specified materials from our members and weight them in accordance with their yearly sales figures. The weighted average price change is then published. The reason we do this is if there are significant price changes, we can provide a suitable instrument for our members to reduce time-consuming negotiations with customers – because the published numbers are proved and reliable.”

How do you see the German fastener market developing and what are DSV’s plans for the future?

“From my point of view, the German fastener market is not likely to grow significantly in the coming years, but there are still opportunities within the market. The development of high-tech fasteners and techniques offers potential for the future, but there needs to be more qualified employees within the sector. There will also be the fast changing demands in the automotive field and the need for further globalisation. Big companies must follow OEMs regarding worldwide local production. Smaller companies who are not able to follow OEMs into foreign countries must develop unique features to survive in the local market. As an association, we will look to continue to strengthen the technical power of our members, through training, education and R&D projects.” www.schraubenverband.de

“As an association, we will look to continue to strengthen the technical power of our members, through training, education and R&D projects.” 46 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

Image

MADE IN GERMANY

Investing in the future Böllhoff Group is coming to the end of a three year large-scale €172 million investment package into its infrastructure, with the aim to prepare the Group for future growth opportunities. Editor Will Lowry visited the Group’s headquarters in Bielefeld, Germany, to speak to co-CEO Michael Böllhoff about the strategy behind the investment and the benefits it will offer.

hree years ago, Böllhoff Group made the decision to invest into its infrastructure – including planned extensions, new logistic centres in Germany and France, as well as further investment in its infrastructure in China and India – all of which was based on the Group experiencing growth in the market. “Whilst there may be a current downturn in the economy, it was definitely the right decision to invest in this infrastructure, as we believe technological trends will continue to have a positive impact on the business,” states Michael Böllhoff. “The investment enables us to prepare for the next growth spur and we want to ensure we keep ourselves as a leading company in the fastening sector.” The largest investment of the project was into the new logistics centre (pictured above) in Saxony, Germany, as a greenfield operation. “The choice of location was based on the proximity to our customers operations both in the southern part of Germany, as well as to eastern European countries,” mentions Michael. “By having a greenfield operation, we could also optimise the logistical and material flow throughout the centre. We have also included a good level of automation, including fully automated and semi-automated processes.” Michael continues: “Logistics is a core competence for the fastener industry and the requirements from our customers are changing dramatically. For a lot of our catalogue business it is about availability and competitive pricing, which makes having a central logistics centre, such as the one in Saxony, vital. The plan is to open the centre in Spring 2020 and both this centre, and the logistics centre in France, will offer us significant benefits for the future. Our aim is to provide customers with value added logistics and combine this with being a supplier of engineered solutions beyond riveting, self-piercing, thread technology, as well as plastic solutions.”

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Being prepared for uncertainty

As a business, Böllhoff is always preparing for future trends as well as developments within the market. “The overall trend for the last two or three years has been different to what we have lived through in the last twenty years,” explains Michael. “Since the 1990s we have seen a push towards free trade and open borders. However, this mindset seems to have changed, and we see this in the USA, in the UK regarding BREXIT, in Spain with Catalonia, in Hungary, even with certain trends in Germany. All these pieces mean we are at a point where we have to think differently and be prepared for more protectionism and the possibility of more border control, and so forth.” Michael continues: “Whilst we need to think differently, our production network and global structure will still be orientated to free trade. We are not rolling this back. We just need to consider what will happen if the current trend for tariffs continues in the future.” Regarding the current slowdown, Michael believes different markets have reacted in different ways. “Some markets have reacted earlier than others, with some only just starting to react. For instance, the German market has only recently started to feel the slowdown, whereas the Chinese market reacted a lot earlier, as did other Asian markets such as

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MADE IN GERMANY India. However, I believe a lot of this downturn is cyclical. In Europe we have experienced nine years of growth, so it is not a surprise that we see a certain downturn. It has simply been accelerated by the current geopolitical issues, but you could see a downturn coming, even two years ago.” A market that has been a key growth driver over the last eight years, but is now feeling a slowdown, is the automotive sector. “It is without doubt very challenging times for the automotive sector. However, we believe the technological requirements regarding e-mobility, autonomous vehicles and carsharing aspects, will continue to give fastener companies opportunities and at Böllhoff we are prepared for this through new products and innovations. We are positive that individual mobility in the form of cars will still be the main driver of mobility for the population around the world in the future, and our innovative products will be able to service the new technological trends of the car industry.” “We see the push to e-mobility continuing and we are working towards those forecasts that predict 25% of the market will be e-mobility and hybrid systems by 2025. Whilst we are following the developments of our customers towards e-mobility and hybrid engines, we still don’t see the use of diesel engines stopping completely. The reason is pure e-mobility is a great solution for city travelling and the infrastructure for these areas will develop rather quickly. However, I am doubtful e-mobility is the right solution for long distances and rural areas. We need more time to develop the technologies and infrastructure for this in the long-term.”

Working with customers

Thanks to its global network, Böllhoff is able to liaise with customers worldwide on e-mobility projects, whether it is the west coast of the USA, in Europe, or in Asia. “We have a network of global organisations that enable us to work closely with our key customers. We are there to listen to their needs and we have the ability to make the necessary product developments. We have already made some nice developments towards e-mobility with our customers and we are excited about the opportunities it will bring in the future.” “For instance, there is a huge

L-R: Michael and Wilhelm Böllhoff

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push towards e-mobility in Asia with a lot of companies developing on this trend and coming into the market, especially in China. Our approach is always to work with them, and if they move into Europe or North America we already have applications on those cars. However, I do believe companies such as VW are also very well positioned to follow these trends with new platforms to push into this market. It shows there are opportunities globally and thanks to our international reach we can follow the trends in all three markets – North America, Europe and Asia.”

Constant innovation

As a 142 year old company, Michael underlines that Böllhoff couldn’t have survived without constant innovations. “An innovation is any new idea; whether it be the way we do marketing; the way we produce our fasteners; or how we develop new products. Since the very beginning it has been a culture that we have looked to keep at the forefront of the business. The market and the customers’ requirements are constantly and quickly changing. We cannot do the same things we did as little as ten years ago – not the same products, the same processes, or the same services. All these things are changing quickly, and innovations are a key factor in this.” A big part of Böllhoff’s ability to continuously innovate is its commitment to talking and listening to its customers’ requirements and understanding their long-term issues and the technological trends. “You need to understand these trends and requirements and then develop the right solutions through product development,” mentions Michael. “The room to innovate comes from new customer assemblies, our internal manufacturing processes, as well as the increasing quality requirements from the end user customer.” When looking to the future, Michael is clear Böllhoff’s aim is not to be just an innovation leader. “Innovation is undoubtedly important, but we want to be a competence leader, which is the combination of being an innovation and cost leader. We are dealing with competitors and markets that need the innovation but also need the efficiency and effectiveness of our solutions. We cannot just sit back and say we are specialised in these technologies. We need to have a strong cost culture, be effective, as well as innovative. Only by doing this will we be able to attract new business and opportunities to grow.” www.boellhoff.com

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Felo stands for quality tools A manufacturer of screwdrivers and screwdriver bits, Felo has established itself as one of the leaders in this specialist segment when it comes to quality, innovations, and also a great variety of different product lines.

elo Werkzeugfabrik has 140 years of experiencing in manufacturing hand tools and for the last 69 years has been located at its current site in Neustadt, near Marburg, Germany. “The company was originally founded as ‘Hammermühle’, a factory for forged tools such as hammers, pliers and screwdrivers, before we changed the name in the 1950s to Felo,” explains Martin Holland-Letz, CEO at Felo. “Since the very beginning the company has been known for its commitment to innovation and quality, and has been very export focused.” Today, 80% of Felo’s products are exported. The brand is active in 45 countries worldwide, with its main markets in Europe and the USA. “The US market is our biggest single market outside of Germany, which underlines our commitment to international growth,” states Martin. “Other important markets for us include Spain and Italy, but we also have a good market share in eastern Europe, and in South America – especially Argentina and Chile.” Martin continues: “We are a company with a truly global outlook. For instance, we utilise marketing material in 20 different languages and our sales team can communicate with customers in seven different languages. We are proud of our global reach and are looking to grow even further in the future.”

Full manufacturing competence

Felo’s 230 employees produce 1 million bits, 60,000 individual blades, and 750,000 complete screwdrivers per month. “This production is across our two plants situated here in Neustadt as well as in Hungary,” clarifies Martin. “At Neustadt we have a very flexible production that includes an in-house design department, a tool and die making workshop and in-house heat treatment, all staffed with a highly trained and motivated workforce.” When it comes to manufacturing screwdrivers, from machining the raw material up to customised packaging, there is a wide variety of production steps necessary – with Felo having the full competency for every step. “For screwdrivers we have the whole metal process in-house, starting from processing the steel wire, as well as the heat treatment, and the entire injection moulding of the plastics using robotic support, plus the packing and logistics,” points out Martin. “The only production step not carried out in-house is the chrome plating. This is due to it being, environmentally, a very sensitive process, which is why we work with specialists.” Felo also has a comprehensive and growing range of insulated tools. Each item is certified and tested according to the highest standards for electrician’s tools. Each individual insulated tool is also tested upto 10,000 volts to guarantee conformance and safety.

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Growing to meet demand

Felo has been increasing its production capabilities over recent years with the addition of new machinery and a new automated warehouse. “The automated warehouse was put into operation last year with the aim to help improve the picking process, and service, and give us more space for stock,” mentions Martin. “The new automated warehouse includes 5,500 containers, which is a lot more than we could previously stock, but it still takes up a similar amount of space as the automated warehouse is a lot more compact. The products are picked automatically and get moved to the logistics area where they are packed for shipment. The company is also currently working on an additional building that will help create further space within the production department. “The new building has two levels, with the main hall housing injection moulding machines, as well as the tooling and die department, while the upper level will be used for offices of production related departments,” explains Martin. “This will then create further space in other areas of production, so we can continue to add more new machinery w h e r e necessary.”

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MADE IN GERMANY Inspiring customers

Felo states that one of its key missions is to inspire its customers with the innovations it introduces to the market. “Often people will think a screwdriver is just a screwdriver and it cannot be improved. However, over the years we have introduced a lot of additional features that make the products better and different to what was available on the market before,” states Martin. “History tells us there is always room for improvement and the development of technologies helps open new doors continuously.” Martin adds: “We are focused on a very niche area and we concentrate all our efforts on these products. This brings us to a level of innovation and quality that is incomparable to companies who are more general in the tools they provide.” An example of Felo’s commitment to innovation is the thought process involved in the design of its ERGONIC ® handle. “Ergonomic handles are very popular within the market and a lot of companies have different designs for the handle. We therefore decided to look at the definition of an ‘ergonomic shaped handle’ and as per the definition ‘it is a handle that makes it easy for the hand to shape to the handle’, but we saw that as a compromise. Why should the hand adjust to the handle? We thought it would be better if the handle could adjust to the hand.” These considerations resulted in Felo’s invention of the ERGONIC handle. The impact proof handle core made from

polypropylene is coated with durable elastomer with embedded cells of highly flexible plastics. Under torque, this leads the handle to deform and interlock with the user’s hand – giving a lot more leverage and making the installation easier. “The ERGONIC screwdriver has been on the market for several years and has proved very popular with customers due to our unique view on what truly counts as ergonomic.”

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As a German manufacturer one of the biggest challenges for Felo is finding the right people it needs. “I am not talking just about engineers or highly qualified roles, I am talking about everyday jobs,” explains Martin. “The cost for labour has gone up significantly, not just within Germany but across Europe. It is almost impossible to hire people at our plant in Hungary – where we are looking at a double-digit increase in labour costs.” To help it overcome these challenges, Felo is looking further into robotics and automation. “We have used robotics in our injection moulding department since the 1980s and it is already a big part of our production process. The role it plays will only grow in the future,” mentions Martin. “We have also recently introduced a robotic system into the grinding department, as we couldn’t find people willing to commit to the training.” “Investing in automation will become a key factor for every business, even if the process gets a bit more expensive as a result. The reason why is because you get the reliability and repeatability guaranteed rather than a revolving workforce.” Martin concludes: “We are a proud German manufacturer and thanks to our experienced workforce, as well as the continued addition of automation, we will carry on providing brilliant products – combined with an excellent service level – to customers around the world. We currently stock more than 2,000 products under the Felo brand and about the same number of special/private label products in our warehouse, which will help us meet our ambitious growth targets for the future.” www.felo.com

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MADE IN GERMANY

Panos Spryidis Chair of fastening technology, TU Dortmund University Panos Spryidis recently became the chair of fastening technology – a new position for the faculty of architecture and civil engineering at TU Dortmund University. Editor Will Lowry visited the Dortmund campus to speak to Panos about his new position and the role fastening technology plays within the university’s curriculum.

hilst he was still studying at university, Panos had the opportunity to visit the University of Life Sciences and Natural Resources in Vienna, Austria, where there was already an ongoing research group on fastening technology – working in close collaboration with the industry. “I ended up doing my doctoral work on this subject and worked with brilliant people, including experts from Hilti and fischer,” explains Panos. “It was interesting to see how two big competitors worked very tightly together, in a very good collaborative environment, to promote the know-how in the area of construction fixings and fastenings in concrete.” After this Panos worked as a consultant and practicing engineer in London on projects including Crossrail and the London Tube upgrades, as a structural tunnelling engineer. “It was already my idea when I finished my research work to go out and get a good understanding of industry practice and the business environment, then draw this technical and industry/commercial knowledge back to a university.” That university was TU Dortmund after it decided to expand its coverage of fastening engineering. “I started at the university at the beginning of 2018 and I recently became the newly introduced chair of fastening technology,” mentions Panos. “The term fastening technology is actually a direct translation from the German term ‘befestigungstechnik’. However, the role expands to constructional engineering and involves fastening and assembly engineering principles.” Whilst there has been a legacy of expertise in fastening technology at TU Dortmund, it has now become a topic of its own, which shows the intention of the university to solidify its expertise in fastening engineering. “We belong to the faculty of civil engineering and architecture, which is another special aspect of TU Dortmund. Civil engineers and architects sit together in many of the courses and do projects together, which helps them understand neighbouring but differing disciplines.” As part of both the Bachelor and Master courses for civil engineering and architecture there are different modules that focus on structural engineering, architecture and city planning, as well as construction management, including building services. “Fastening technology is connected to all of these different modules,” points out Panos. “Our main focus is structural engineering, but we do a lot of work in regards to worker safety, construction logistics and Building Information Modelling (BIM).”

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If there is a big shift towards off-site construction and installation via robotics or automation, does this mean we need to rethink how the fastening is designed?”

Regarding fastening technology, Panos highlights that there are essentially two courses. “One is a basic course, where students understand the different technologies, the different applications, and the installation principles, which is a very important part of our field. We are talking about a lot of manual work, so there are a lot of risks of defects in installation. We try and train the students to manage a project where fastenings are included, so they can understand what they need when they have to install some fastenings. This covers safety critical fastenings and non-structural fastening for all fields of application.” Panos continues: “There is also an advanced course, which is typically taught to structural engineering Masters students. The focus is on teaching the actual design for fastening into concrete and masonry, with special focus on EN 1992-4 2018 Eurocode 2 – part 4. This is the new design standard, and it is an obligation for structural engineers for when they deliver a design project to have all fastenings designed with this Eurocode.” The aim is for students of both courses to have more or less all the available knowledge related to fastenings – from structural engineering details to material science, to what is going on in practice, as well as how to use design software. Plus, what the European technical approvals dictate, and how they are developed. “The students will be able to understand how a fastening is manufactured, designed and installed – the whole fastener process. This shows the importance of fasteners is growing within the educational sector and I am actually visiting a lot of other universities abroad to give some lecturers on fastenings.” With risk, reliability and safety vital parts of a fastening’s design and performance, Panos believes there is movement within the civil engineering market for the development of risk/performance-based design. “The way we design structures today is very much based on empirical observations with a lot of added safety. This is sometimes expensive and also not realistic. With performance-based design you are looking at the performance for the everyday use and the performance for extreme situations.” “We also have the aspect of life cycle, in what we do. Historically, we have mostly focused on how the structure will behave as soon as it is commissioned. However, now the aspect of sustainability and long-term behaviour is coming into play. We are talking about designing under a lot of uncertainty. The operation is something we can possibly predict, but it still has a lot of fluctuations. The extreme events is something we have difficulty to predict, but we somehow consider it.” “Then the long-term performance of materials and fastenings, and the changing actions of loads on anchors over time, is something we also have difficulty to predict. If we design based on this type of focused performance requirements, we come up with more realistic and economical, as well as safer solutions. In the end it all comes down to risk, what is the risk we can take. If there is a big event – earthquake, fire, flood – how will the structure handle it?” Another area the fastening department is looking at is the digitalisation of design and construction. “Currently companies have CE Marking for their products, but they are finding more and more they need a digital twin, which includes all the relevant details. This means the information of the product does not just stay on the paper, but it can be communicated in a standard manner via digital planning or a design document.” “At the moment we are looking at what is needed and how we can combine it with the other software we have – what is the best way to use it, how can we improve it? We are also talking to end users about what they need regarding the CE Marking information and ensuring it is available digitally.” Other areas the department is looking at includes the use of fastenings with new materials, for instance carbon fibre reinforced materials; applications of retrofitting; as well as development of anchoring products.

“We are also currently collaborating with some fastening companies using applied and fundamental research and also supervise the training of labour staff for the installation of fastenings,” mentions Panos. “We are also open to working with further fastener companies, who are looking to develop new products or test the capabilities of their existing products.” Regarding trends within the construction section, Panos believes the shift from on-site construction to construction off-site will continue to develop. “Fixings are strongly related to manual work and I am certain there will be a large shift from on-site to off-site construction. This type of work leads to the opportunity for the integration of fastening installation to a robotic or automated procedure. However, this creates a whole host of other questions regarding fastenings.” “Traditionally, fixings for the construction sector are conceptualised for manual installation. If there is a big shift towards off-site construction and installation via robotics or automation, does this mean we need to rethink how the fastening is designed? Typically, fixings are made to be torqued by a wrench, which is operated by a human that can pull it to 20kg – 30kg. However, if you swap this with a robot or automated machine, the installation will be done a lot quicker and with more power and precision, which creates a lot of opportunities and challenges. So, on one side we have the engineering community that supplies new concepts in the design and construction and on the other hand we have the acceleration of off-site construction where fastenings could play an important role.” “Either way, fastenings are some of the most highly engineered construction products on building sites. They are manufactured with precision and with tight manufacturing specifications, which means there are a lot of opportunities for the future.”

Whilst there has been a legacy of expertise in fastening technology at TU Dortmund, it has now become a topic of its own, which shows the intention of the university to solidify its expertise in fastening engineering.” FASTENERANDFIXING.COM 57

MADE IN GERMANY L–R: Ralf Kaltheuner, Joachim Rohwedder and Goetz Kaltheuner

Strengthening the family bond For the first time in over 50 years the family behind Puehl will once again be involved in the day-to-day running of the business from 2020 – with the fourth generation, Dr Goetz and Ralf Kaltheuner, joining the operational board together with Joachim Rohwedder (CEO).

ver the last 50 years Puehl has always had an external managing director running the company. However, at the start of 2019 the shareholders took the decision that the family should get back involved with the business operation. Both Ralf and Goetz started in January this year and have been working across each department to further understand the day-to-day operations. Since October 2018, the company has been led by another family member, Joachim Rohwedder, the father in law of Ralf Kaltheuner. He will continue to support the Kaltheuner brothers when they join the new operational board and take over responsibilities for different departments in January 2020. The Kaltheuner family has the knowledge of the market and understands the history of the business, which were key factors in the decision to introduce the next generation. “Our great uncle founded the company, before it moved over to our grandfather and then father,” explains Ralf Kaltheuner. “We are now the fourth generation and we will continue to develop the family business for the future – offering the reliable and flexible service, which we have built the Puehl name on. Since starting we have been supported by our staff to enable us to learn more about the day-to-day operations, which has been a huge benefit.”

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Puehl manufactures a wide range of stamping parts that go into a variety of sectors, which means it is not beholden to one particular market.”

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MADE IN GERMANY

Goetz Kaltheuner adds: “For the employees it shows sustainability, because if the family is involved in the company it helps underline the family principles that have made Puehl such a success. Our aim is to continue with these principles and develop new opportunities to help us grow in the future.” Puehl manufactures a wide range of stamping parts that go into a variety of sectors, which means it is not beholden to one particular market. “This is a very big plus for us, as it means if a certain sector is struggling, we have other fields to focus on,” points out Ralf. “For instance, currently there is a slowdown in the automotive sector, as well as the German economy as a whole. However, only 10% – 15% of our business is for the automotive supplier industry, so we have not been impacted as much.” To further counteract the slowdown, Puehl is also looking to increase its sales activity within Europe. “We have sales representatives in France, Spain, Portugal, and we are currently looking for representatives in Italy and eastern Europe,” mentions Goetz. “We want to expand in these areas and be more proactive to grow our customers, alongside our existing customer base.” A key factor in developing its customer base is the company’s commitment to investing in its infrastructure and the service it provides to its customers. “We recently invested in a new ERP system, which has played a huge role in helping improve our service,” states Goetz. “Introducing it was a time-consuming process, but it was vital to enable us to efficiently handle the volume of products and orders we work with every day.” The new system has helped Puehl improve the processes in its quality management, as it can track parts throughout the production chain. “It gives us a great overview of the entire production process and allows us to offer more possibilities to our customers,” adds Ralf. “We will continue to work on our ERP system and look to optimise it where possible. We want to make sure we are as cost-efficient and process effective as possible, and the ERP system will help us streamline operations and make our processes stronger.” Another area in which the ERP system has had a big impact is with offering ‘frame contracts’ to customers. “Our ability to offer ‘frame contracts’ is a big advantage of working with us,” says Goetz. “We offer six or twelve months ‘frame contracts’ where we stock customers’ parts in our warehouse. A big plus for the customer is they only pay for the parts once they are delivered. This means they do not need to keep the products in stock, and they can request them when they need them.” Puehl ensures it always has a portion of each product in stock, guaranteeing quick delivery to customers. “We have several agreements with customers regarding time frames and delivery, and we are seeing a growing interest in this area,” adds Ralf. Puehl has also invested further in its in-house tool shop, where all the tools for its production are produced. “We already have a high-level of machinery within the tool shop, which enables us to build our tools in-house with good quality and shorter reaction time,” explains Goetz.

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We have a vast amount of experience and knowledge within our different departments, who can all help customers even further with their enquiries.” “The investment means we have been able to replace older milling and eroding machines with the latest technology. These newer machines are quicker, faster, with a better quality, and help improve the overall department. Improving the efficiency of our tool shop was crucial, because if you cannot produce the tooling it can hold up the entire process.” In addition to investing in its services and infrastructure, Puehl is also looking to focus more on increasing the contact with customers through key departments within the business – not just its sales team. “Having contact with customers is very important, and having a personal touch is even more so,” states Ralf. “We have a vast amount of experience and knowledge within our different departments, who can all help customers even further with their enquiries. Our experts can talk to customers about options regarding changing from a turned part to a stamped part or help with designing more special and complex parts. We can give customers technical know-how and support so they can produce at volume at a better price, with a better quality.” Puehl is very good in the bigger sizes, where turned parts are normally used, meaning it can offer a good alternative. “Thanks to our wide range of machinery, from 100 tonnes up to 1,000 tonnes, we can produce parts from M3 – M72, with the possibility of M80, and offer customers a wide range of high performance solutions,” explains Goetz. “Customers are checking parts more and more and the quality level is always increasing, so being able to reliably supply high-quality products is essential.” “As a business we are well known within the industry and by working with customers we can continue to provide the products and service that has established Puehl as a leading brand for stamping parts,” finishes Ralf. “As the fourth generation, we are looking to continue the family philosophy whilst growing in partnership with our customers.” www.puehl.de

Becoming a global player In 2019 Teudeloff celebrates its 25th anniversary as a leading player within the recess pins and punches sector, with customers in more than 30 countries – mostly in Europe, the USA and the Far East.

ounded in 1994 by Holger Teudeloff, the former trading company points out that it has rapidly developed from solely focusing on the German market to becoming a global player within the fastener industry. The key competences of Teudeloff, and its production at Tooling International Limited (TIL), clearly lie in recess tooling such as punches and pins for fasteners in cold forming. Its range includes all geometries, as well as Torx®, Torx® plus, Six lobe, Pozi®, Phillips®, Hexagonal, 12-Multipoint, Bihexagonal, plus specials, standards, and to drawing. Thanks to its development and optimisation of tool life, costs, and productivity, Teudeloff is able to promise guaranteed tool supply, supported by a quick and reliable delivery. According to its motto ‘nothing is impossible’ Teudeloff’s development department is also able to work with its customers on individual requirements – designing innovations that ensure the customer is fully satisfied. “By working with TIL we have developed tools that allow 20 times longer service life than comparable competitive products,” explains Teudeloff. “The internal quality management also checks after each production step that the highest precision in terms of geometries and tolerances is maintained.” “These services have been valued by our customers for 25 years, which has helped make us one of the main suppliers in the automotive and aerospace industries, as well as screw production,” states Teudeloff. “We have the biggest Torx® stock in Europe, with almost all sizes and penetration depths, in various materials and coatings. Among them our top quality CodeT®.” www.teudeloff.de

TEUDELOFF & TOOLING INTERNATIONAL

WE THINK AHEAD WORLDWIDE

AUTOMOTIVE • AEROSPACE • WOOD • CONSTRUC TION • WHITE GOODS

QUALITY SERVICE SECURITY PERFORMANCE BS EN ISO 9001

world class recess punches & fastener tooling info@teudeloff.de (Europe) sales.us@teudeloff.de (America) sales.fe@teudeloff.de (Asia)

Teudeloff GmbH & Co. KG Rodbachstraße 37 74397 Pfaffenhofen, Germany Tel: +49 (0)7046-88 0 84 0 www.tooling-international.com www.teudeloff.de

your trust worthy partner for more than 25 years

MADE IN GERMANY

The ‘Mittelstand’ success story By Dr Axel Hunsche, managing director at TesT GmbH Strategically positioned at the heart of Europe, Germany is the fourth largest economy in the world – with machinery as one of its strongest exporting sectors, setting quality standards globally. Of course, companies like TesT benefit from this stellar reputation for German engineering.

his reputation is well founded in the German tradition of excellent education and a high appreciation and commitment for precise and efficient work. This self conception creates a highly motivating business environment, in which innovation and progress are the driving forces, challenging the industry to meet international expectations. Another unique factor for German businesses is the so-called German ‘Mittelstand’ – the famous small and medium-sized enterprises (SME) – that build the strong foundation of Germany’s economic success. As an SME ourselves, TesT GmbH notices the advantages of being a small family-owned and led company every day. Our size and structure enable us to match various customer requests on an international level, including custom-made solutions for special requirement orders, by acting in a more immediate and flexible manner than bigger companies. On the other hand, family businesses represent commitment and reliability. They are in the special position of being able to commit wholeheartedly to long-term goals, being more independent of investors than large corporations. We can give business time to develop so as to form strong and long-lasting partnerships. This kind of fast operating on the micro level and patience on the macro level is a key factor for the ‘Mittelstand’ success story. The German measuring and testing technology sector in particular is characterised by small and medium-sized companies. They represent the world leaders of several niche markets, carrying almost one third of the worldwide trade volume of the industry, which was €3.7 billion in 2018. Also, the large variety of client industries give the measuring and testing technology a clear advantage in opportunities for economic growth. Knowing that the only constant of our time is change – addressing keywords like digitalisation or culture shift – the hidden champions of the German SMEs find themselves in pole position for transitioning successfully into an

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everchanging future. Looking at the fastener market, we are, for instance, expecting changes in the technical field of renewable energies and electromobility. New cars and mobility concepts will bring new construction challenges with different fastener applications than conventionally used before. With its energy system transformation, the so-called ‘Energiewende’, Germany is one of the leading countries in the world to establish a more sustainable energy supply. Facing the urgent challenges of climate change, there is not enough that can be done to promote the necessary transformation. This puts a lot of pressure especially on the industrial sector. In this serious situation it is our duty to seize the opportunities that come with new technologies, both in their advancing implementation and distribution. For instance, the incorporation of renewables into the existing power grid includes the expansion of wind farms. Wind turbines require the installation of enormous, specific bolts, which obviously need to be quality tested in specially constructed machines. As the world’s first and only manufacturer, TesT develops screw testing machines for sizes up to M80, which is even bigger than the largest screws used in the ground fixing of wind turbines. With our mindset of challenging the status quo, we are equipped for the technologies of the future. www.test-ag.ch

90 years of precision and growth For almost a century, the name HONSEL has been a fixed term in the fastening industry for high-quality, innovative fasteners and processing solutions ‘Made in Germany’.

stablished as a partner for automotive manufacturers and suppliers, as well as for large-scale industry, in a wide variety of sectors, HONSEL Umformtechnik is known for its high competence and capacities for producing customised parts in cold forming – producing more than one billion parts per year. In addition to blind rivet products, developed according to customer requirements, the HONSEL range includes blind rivet nuts and studs, modern captive sleeve bolt systems (powertrain fasteners), coil threaded inserts for heavy-duty connections in lightweight construction applications, as well as self-clinching parts. HONSEL’s location in Fröndenberg, on the edge of the Ruhr metropolitan region, offers perfect conditions for development, production and worldwide distribution. The more than 10,000m² of production space available was again expanded this year by HONSEL – with a third plant and fully automated warehouse added. A new office building is also about to be completed. HONSEL has more than 30 five and six-stage presses for cold forming up to 20mm wire diameter. Furthermore, the company’s in-house processing possibilities include partial inductive annealing and hardening, machining, plastic sheathing and surface treatment. HONSEL also has in-house

toolmaking capabilities and is a specialist in prototype realisation – guaranteeing fast and flexible reaction times. “Our team of specialists are able to develop and manufacture the right tools for reliable and economical processing. From automation components for special machine construction to integrated process monitoring,” explains HONSEL. “Topics such as optoelectrical 100% control and closest tolerances are standard and daily practice at HONSEL, as is the successfully mastered challenges of asymmetrical geometries and the most complex degrees of forming.” The highest quality in all areas is a top priority for HONSEL, as is the close cooperation with the more than 400 HONSEL experts at the worldwide locations of the HONSEL Group. www.honsel.de

Friction Coefficient Testing Machines for Screws, Bolts and Nuts Friction Testing • Vibration Testing • Torsion Testing • Tension Testing

• • • •

For fasteners from M2 up to M80 Patented transducers Integrated heating-solutions Extensometers optional Conform to standards: ISO 14399, ISO 16047, company standards from FIAT, GM, Hyundai, PSA, Renault, VW and many more

TesT GmbH • Helena-Rubinstein-Strasse 4 • D 40699 Erkrath • +49 211 209903-0 • test@test-gmbh.com • www.test-gmbh.com TesT AG • Bösch 63 • CH 6331 Hünenberg • +41 41 785601-0 • test@test-ag.ch • www.test-ag.ch

MADE IN GERMANY

Max Mothes the manufacturer Celebrating its 100th anniversary in 2018, Max Mothes has a long and proud history as a leading distributor within the fastener industry. However, since 2012 the company has changed its focus to become a manufacturer of high performance technology.

artin Schermbach, managing director at Max Mothes, explains: “In the past we were one of the biggest distributors in Germany and Europe and we were known for our depth and range of stock. However, due to competitiveness of the distribution market, we decided we would change our focus to manufacturing.” Thanks to its customer base and experience of over 100 years, Max Mothes was fully aware of the type of manufacturing requirements demanded within the market and set out to meet those needs. “A key factor of us developing our manufacturing capabilities was our relocation to our new facility in Neuss,” mentions Martin. Max Mothes’ previous head office had been in Düsseldorf city centre, but there was no room for expansion – which is why the company decided to move to its new location in Neuss. “The new site has enabled us to expand, with the production, manufacturing and logistics covering around 20,000m2,” points out Martin. “The whole site is around 60,000m2, so we have a lot of space to extend in the future if necessary.”

High performance manufacturing

The capabilities within Neuss include CNC machinery and inductive heating, as well as a clean room. “We have heavily invested in a wide range of CNC machines over the last four years for new projects and products,” highlights Martin. “We have also built up our own production machines and tooling department to ensure we have a good production flow, as well as setting up our own laboratory and prototyping service.” Through its strategic partnership with Sumeeko, which started in 2018, Max Mothes also has access to further manufacturing capabilities in Germany, Italy, China, as well as two factories in Taiwan. “Through the partnership we are able to manufacture via cold forming, hot forging and machining,” states Martin. “By working closely with our customers, we are able to make sure we are providing the service they require. If they have smaller quantities, we can do parts by machining; if they have big quantities, we can do it by forming or hot forging. We simply analyse the part and look at what will be the most efficient and cost-effective manufacturing process.”

System connectivity

To add to its production capabilities, Max Mothes also introduced a new ERP system two years ago, which enables it to manage both external and internal processes. “Introducing the ERP was a long process, but we wanted to make sure we benefited from the system as much as possible,” explains Martin. “The first thing we did was to sit down and look at each process for every department. We then looked at what the standard is for the ERP system and worked out how we could optimise our processes to make them efficient and effective.

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We are now seeing the benefits of the hard work and we are able to analyse data from across all our sites around the world to give us a complete overview of each production technology.” To go alongside its production capabilities, Max Mothes also went through a targeted hiring strategy to add more manufacturing and engineering experience to the business. “We needed to be able to work alongside customers and sit down with them and see how we could help them reduce costs whilst still offering a high-quality solution. We have added experienced manufacturing professionals and can now work very closely with customers.”

Max Mothes products

In addition to developing its manufacturing capabilities and knowledge, Max Mothes also started to develop its own product lines, including sealing nuts and MOTHES FIX. “In the area of sealing nuts, we have developed a nut that reliably prevents the escape of liquids and gases – providing a firm, permanent fit due to the securing device,” mentions Martin. “This has been made possible by the combination of nut body and a sealing ring that is resistant to oils and solvents. When tightening the nut, the sealing ring presses under high pressure in a specially cultivated recess on the metallic nut body and at the same time against the wall of the through bore. Even after repeated loosening and tightening, the connection remains tight.” The sealing nuts are available from M6 to M20 with different surfaces. The temperature resistance ranges from -40ºC to about 110ºC and the pressure load is over 640 bar. The MOTHES FIX is a captive sleeve and bolt connection, which can be supplied on pre-assembled modules directly to the production line of OEMs for assembly. “The MOTHES FIX is a screw that is fastened even before installation and is an indispensable part of modern connection technology,” points out Martin. “The resulting savings potential in the areas of logistics, assembly and quality are enormous and can be generated immediately. Put simply, the MOTHES FIX is a small component with a big impact on processes.”

Distribution mindset

Whilst Max Mothes has changed its focus to production, it is still using its distribution experience to ensure it is providing customers with a first-class logistics service. “Whilst distribution is no longer our main target, we can still offer a high-quality logistical service, which gives us a big advantage against other manufacturers,” explains

Martin. “We still have the knowledge and size of a logistics operation that enables us to offer key services such as bin systems and scanning systems. We can combine our manufacturing and logistics capabilities to provide customers with one focal point.”

Automotive focus

Currently 40% of Max Mothes production is focused on the automotive sector – both OEMs, as well as tier 1 and tier 2 suppliers – with the company also recently achieving the IATF 16949 certification. “Our main automotive business is for safety systems, such as steering columns, braking systems, transmissions, etc,” points out Martin. “These are high-quality parts and play critical roles within the automotive market, which highlights the quality of our products and the trust our customers place in us. When you work with the automotive industry it means your products have to be of the very highest quality and you need to be able to provide a first-class service – there can be no delay.” “A big opportunity for us going forward is the e-mobility sector where we are already producing a lot of products – predominately made from copper. We will look to continue to develop this area in the future, but we still see the traditional car industry being our main focus,” states Martin. “The parts we are producing now are only just going into production and we will be producing them for the next 8 – 10 years. We therefore do not see any dramatic changes. However, if there are further developments in e-mobility then you never know what will happen in the future. That is why it important we are able to provide a quick response to customers’ needs and be flexible.”

Future markets

Max Mothes production is currently based on the ramp up from automotive customers that it originally attracted when it first started manufacturing in 2012. “Our production is focused on new parts, with the quantities growing over the last two years from a few hundred to tens of thousands,” points out Martin. “However, we don’t want to be dependent on solely automotive. That is why we are developing other sectors, such as commercial vehicles, construction and agriculture, renewable energy and wind power, as well as mechanical engineering.” “Currently 80% of our development is within Europe, but we have a global network that means we can supply customers around the world. It has been a big challenge changing from a distributor to a manufacturer, but it has been one that we have relished. We have now established ourselves within the market as a key production partner that has wide range of manufacturing capabilities, backed up with an in-depth technical knowledge.”

FASTENERANDFIXING.COM 65

MADE IN GERMANY

BiERBACH® stands for nails

BiERBACH® is an established name within the European fastener market that was previously known for its range of timber and construction connectors. However, after a change of strategy the company has now switched its focus to its specialised nail production.

anaging director Matthias Bierbach explains: “As a business we were in between two chairs regarding timber and construction connectors. We were among the three top manufacturers in Europe for this product, but we could not compete with the leading producer – from an R&D point of view. However, we were still a lot better than the lower cost alternatives from Asia, which meant we could not compete with them on price either.” In 2013 BiERBACH® therefore sold the timber connector business – the brand names, patents, tooling for the machinery, etc – to the leading player within the market and decided instead to focus on its in-depth range of special nails. “The first product we produced was nails, so in effect we have gone back to our roots,” mentions Matthias. “We have a vast amount of experience and knowledge in producing nails and can manufacture a whole range of products from a diameter of 0.5mm up to 10mm, and in lengths from 5mm to 440mm.” BiERBACH does not manufacture or sell common nails, instead it concentrates on special nails. “We are still situated at the same site in Unna, near Dortmund, but now we only take up a fraction of the space, with the remainder of the site divided into separate units that are rented to third parties,” explains Matthias. “Using decades worth of experience, our employees can produce a whole range of special nails including timber and construction nails, building nails, threaded nails, nails made of stainless steel, brass, copper and aluminium for specialised use in the building industry, gardening or home improvement sectors, masonry nails, concrete nails, decorative nails, hardened nails, ring shanked nails, as well as steel pins, steel hooks and colour pins, and even hand forged nails for decorative applications.”

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These nails are available with helical, annular, grooved or barbed threading and with ballistic, diamond and pilot point. Coatings available also include galvanic or mechanic zinc coating, organic and inorganic coatings, as well as colour coated surfaces in all RAL colours. “We can also produce nails according to customer drawings and can work with them to offer alternative suggestions that still offer the same high performance, but be more cost-effective,” points out Matthias. Whilst the market for nails is small, Matthias is clear that there are still opportunities to grow. “70% of our products go into construction, but we also find that a lot of our products are used for untypical applications,” states Matthias. “There are not many companies that have the capability and range that we have at BiERBACH, so we see an opportunity to grow into new markets.” Matthias continues: “Often dealers will only carry a few items on stock and they tend to buy these from distributors or from importers. However, by working with BiERBACH they can order small quantities online via our web shop and receive the products within 1 or 2 days.” BiERBACH’s web shop is available in English and German and includes the full range of nail products. Customers can search by building material, properties, diameter, head type, length, material, and shank, and order the exact quantities they want. Through the web shop BiERBACH also offers individual discounts, as well as discounts for resellers. “When we launched the web shop, we thought it would be for professional end users looking to buy directly from the factory. However, nowadays 70% of turnover from the shop is from resellers – as it is very easy for them to buy the nails they need,” explains Matthias. “As the demand for nails is not typically regular, they know they can go to the BiERBACH web shop and get good products at competitive prices. Customers wanting to buy nails are looking for an easy way to purchase them because they are not a focus product necessarily. By using the web shop, we provide a quick and easier method for customers to buy products.” Currently 70% of BiERBACH’s market is export, thanks to its close collaboration with resellers abroad, and it is looking to grow this even further in the future. “We are always interested in collaborating with distributors in key markets where possible and looking to grow together as partners,” closes Matthias. “Thanks to our range, our specialities, and the experience and knowledge within the business, we are able to work with customers and supply over 1,000 different types of nail from stock, which I believe is unique in the market.”

Dip spin coating lines ‘Made in Germany’ Based in Villengen-Schwenningen, in the south of Germany, Reinhardt GmbH is one of the global market leaders for dip spin coating equipment – offering complete solutions from dip spin coating to post coating heat treatment – all from one source, with a ‘Made in Germany’ guarantee.

ith over 80 years of experience in the heat treatment industry and over 30 years in the coating of dip materials, Reinhardt has an in-depth experience and enormous efficiency in providing solutions for customers. More than 100 customers worldwide rely every day on the quality and durability of Reinhardt’s dip spin coating lines in all different types of industry – where material is treated in bulk or on racks. Producing both the coating lines and the connected heat treatment systems means Reinhardt can control and test everything in-house before being delivered to customers worldwide. This includes customised software implementations to fully integrate the Reinhardt lines into the customer’s production process. Being a German company, Reinhardt benefits from German suppliers that are located in close proximity – ensuring quick and efficient communication lines. In addition, German quality standards, and various norms, facilitate the construction and production processes and enable a cost-effective production. “The challenge of Germany being a high cost production country can easily be

overcome by effective production processes and an outstanding product quality, which results in reliable machinery and satisfied customers,” explains Reinhardt. “Being a German manufacturer also means we benefit from highly qualified personnel and vast national research activities, which result in innovative and reliable products that are popular all over the world. Thanks to our existing product portfolio, we are able to cover almost every possible scenario when it comes to dip spin coating and thermal processing.” www.reinhardt.gmbh

NYLON FASTENERS

Fax: (+ 49) 02591/9194- 34

bulte@bulte.com - www.bulte.com

FOR MORE THAN

BÜLTE GmbH - Kunststofferzeugnisse D 59348 Lüdinghausen - Germany Te l : ( + 4 9 ) 0 2 5 9 1 / 9 1 9 4 - 0

MADE IN GERMANY

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MADE IN GERMANY

The benefits of ‘Evotion’ The last time Fastener + Fixing Magazine visited GESIPA® was in November 2017, when the company was at the beginning of its ‘Evotion’ project. Editor Will Lowry once again visited the Thal site to see the benefits of this investment now it is complete.

aunched in 2016, GESIPA®’s ‘Evotion’ project – combining the terms ‘evolution’ and ‘motion’ – involved a €15 million investment in an automated warehouse with 15,700 pallet spaces, as well as the addition of an extra production hall, which would enable GESIPA to bring together the complete blind rivet production at its Thal site. “It was the biggest construction project in the company’s history and saw us double the production floor,” states Michael Hacker, plant manager at GESIPA. “Plus, we added a new automatic 22m high bay warehouse to create further space for stock. Once the buildings were ready, we then had to install the new machinery, as well as the machinery from other plants, which we managed to do by the end of 2018.” Having successfully installed all the machines, the next step for GESIPA was to work on the new structure and strategy of the plant going forward. “I joined the business in May 2018, as we were halfway through the process of installing the new machines, and we analysed the production processes and improved the efficiency of the overall production,” mentions Michael. “For instance, the original plan was for there to be one area for eyelets, one for mandrels, and one for the completion of the blind

rivets. However, we changed it so that we now have a ‘double hall’ philosophy. This is where each hall runs independently and focuses on eyelets, mandrels, and completion. This means if something happens in one hall, we are always able to carry on with our production.”

Automated storage capabilities

In addition to the extra production space, GESIPA also benefited hugely from the automated warehouse. “Normally automated warehouses are associated with distributors rather than manufacturers, but we have found it to be a big positive for us as a business,” explains Michael. “The first, and most obvious benefit, is we are much faster in sending out complete orders, as the system knows where everything is and can quickly pick it for delivery. In addition, we are able to stock raw material in the warehouse and use it to quickly and effectively get the material to the right machines. The software system knows when we are running out of material and can ensure the material arrives from the warehouse to the machine, so there is no delay in production.” The automated warehouse features two entry and exit points at either end, so each production hall has its own access – once again

With the ‘Evotion’ project now complete, the Thal plant fulfils all the blind rivet needs for GESIPA to worldwide customers.”

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BLIND RIVET NUT

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MADE IN GERMANY speeding up the process. Finally, a ‘chaotic’ storage system ensures the most popular products are at either end of the warehouse and less popular products in the middle, to once again optimise the picking process.

Full system connectivity

A crucial part of the manufacturing operation, and the automated warehouse, is the software system behind it. “We are producing 2,500 products, which means we need a good system to manage all the variables. That is why we use SAP,” states Michael. “For instance, by using SAP software we are able to plan and schedule different products (eyelets and mandrels) to ensure they are both ready to be assembled at the same time.” Michael continues: “The new system was introduced at the beginning of 2017, but we have been using a SAP system since 2002. Therefore, we were aware of some of the capabilities and features it could offer. We are now fully integrated, and we have a lot more possibilities open to us on the new the system. Another advantage of the new software is all the different parts of the organisation can communicate with each other – almost all sites worldwide are connected. This means we can see what products are in stock at different locations and the system also guarantees the same commitment to quality, regardless of the products or where they are produced.”

Employee growth

One of the main challenges of doubling its production space was GESIPA also needed to increase its number of employees. “To ensure we kept the high-quality standards that we are known for within the industry, we needed to add new employees and train them on how to use the machines and, more importantly, how to guarantee the quality we demand.” To do this some of GESIPA’s employees from its other production site in Walldorf moved to Thal to work on the machines and help train up the new employees. “The new hall included a lot of machines from the Walldorf site, so having the people from Walldorf made a lot of sense,” comments Michael. “It also showed the commitment and family spirit within the business that these employees were willing to do this.” In addition, GESIPA also introduced a new training academy in 2018 where it could train its new employees. “We had to attract people that were not from our industry sector, so by introducing the training academy we could train them exactly to our requirements. It is also difficult to attract young people and qualified people, so we needed to be able offer them the necessary training ourselves,” points out Michael. The training academy includes a small tool shop for new employees to learn the basics, such as turning, milling and hand working, as well as maintenance set-up. For the more complex training, the academy includes similar machines as in production, so the new employees can learn on like for like machinery. After a few weeks they can then move to the production floor, once they have proven they understand the processes.

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In addition to new employees, GESIPA is also using the academy to train groups of apprentices. “Alongside a standard apprenticeship we also do a ‘Studying with GESIPA’, which is a combination of an apprenticeship with us, as well as studying at university,” points out Michael. “Last year we had two apprentices and this year we had six starting with us, which is a sign the academy is proving a success.”

One plant, one technology

With the ‘Evotion’ project now complete, the Thal plant fulfils all the blind rivet needs for GESIPA to worldwide customers. “We are now fully focused on standard and special blind rivets and we have all the knowledge and experience within the business,” concludes Michael. “Having this knowledge and experience of blind rivets in one location is a big benefit, as it enables us to concentrate on the core competences. As a manufacturer in Germany it is vital to get attractive product costs, by enhancing your processes as much as possible. Thanks to the ‘Evotion’ project we are now in a position to do this and provide a highly optimised production level to all our customers.” www.gesipa.com

THE BEST OF BOTH WORLDS

STANDARD & SPECIAL PARTS

Unique Special Parts and different Standard Parts in stock, all made in Germany. Rely on rfks know-how, quality and customized service.

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MADE IN GERMANY

Evolution not revolution Over the last four years Eurotec GmbH has invested significantly in both its logistics and production capability – following the same growth strategy that has seen it develop from a two person start-up in 1999 to a business with over 150 employees.

arkus Rensburg, managing director at Eurotec, explains: “A lot has happened over the last four years, we’ve increased our storage facilities and built a new production hall, as well as adding new screw production and injection moulding machines. In addition, our turnover and number of employees has increased by 30%.” Originally, Eurotec’s production was situated next to its main warehouse, but after investing in its production capabilities, the company started to run out of space. “We had three production machines for our long screw range, which we can produce up to 3m in length, as well as injection moulding machines that are predominately used for our decking pedestals,” clarifies Markus. “Both types of machine take up a lot of floor space, which meant if we wanted to add further machinery, we needed to move our production location.” Eurotec therefore built a new production hall 500m away from its main head office. “We acquired 14,000m 2 of land and started construction in August 2017. By February 2018 we opened the building and started relocating the machines,” points out Markus. “We moved the machines piece by piece, and we kept two machines running the whole time – so we never had to stop production.” Joern Rueschenschmidt, export manager at Eurotec, adds: “Seeing the machines hanging off a crane was not the most fun, because whilst they are heavy and each part is very long, they are also sensitive like a toothpick. We needed to be very careful to guarantee that when they were in place, they would still provide reliable production and a high-quality product.” Once the machines were moved to the new site, they were brought up to full production speed and Eurotec was able to add further machines to increase the production capacity. “Producing long screws up to 3m is not easy and requires a lot of knowledge and experience,” states Markus. “For instance, there are a lot of

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challenges regarding the straightness of a long screw, as well as with the hardening. Sometimes long screws will look ok, but if the hardness is not correct it can cause a lot of problems. That is why during the heat treatment process, we insist that all of our long screws are put into a vertical rack – so they hang independently and are therefore evenly heat treated. Of course, this is more time sensitive than simply tipping a container onto a belt, but it is a critical factor in ensuring the correct hardness.” Joern continues: “We are currently seeing a trend within the market for larger and taller wooden buildings and therefore the quality of long screws is becoming more and more important. We are very proud of our manufacturing capability and we guarantee we will provide customers with high-quality products, supported by a first-class service.” Eurotec is not only a screw supplier, the company also looks to develop whole product systems. “A good example of this is regarding decking, where we originally started by supplying just the decking screw,” higlights Markus. “Now we supply the whole system behind the screw and can offer the complete range up to the substructure – with a large majority of these parts being made from polyamides.” It was this commitment to providing the complete system that led to Eurotec adding injection moulding to its manufacturing capabilities. “Initially we partnered with a sub-contractor, who we worked alongside to develop the tooling for the injection moulding of decking pedestals. We then purchased this tooling and the sub-contractor became our service partner,” explains Joern. “However, it got to a point where the sub-contractor was too busy to supply us, so we bought our own injection moulding machine. Having it in-house made us more flexible and provided us with reliable production. We could see the benefits, so we continued to add more machines. We now have four and we have plans to add more in the future.”

The injection moulding machines can run 24/7 and include automation to make them run as quickly and effectively as possible. “Adding the injection moulding machines has been a big advantage, as it enabled us to produce the decking pedestals ourselves,” mentions Markus. “In the decking sector there are lots of companies that provide either a decking screw or the pedestal. However, it is only Eurotec that can provide both as one system. We are looking to develop this same strategy within other areas of the market – providing all the products and high flexibility – all from one source.”

Logistics at the core

Similar to its production, Eurotec’s warehouse was also entirely full four years ago, with no room for new products. “If your stock is full there is no material flow, which means even when goods are arriving, you cannot book them in as there is no space,” explains Markus. “Whilst developing our production capability has been an important target for us, our main function is still the logistics

side of the business, which is why we decided to build the next two sections of our warehouse and increase our stock volume from 17,000 pallet spaces up to 25,000 spaces.” “If you were to look aerially at the old warehouse it used to be the shape of a capital letter ‘L’, but after the expansion it is now a square,” points out Joern. “We are a mid-sized company that is renowned for its flexibility, but if you don’t have space, you cannot move any goods. The new warehouse has given us this space and also allowed us to improve the logistics internally and ensure the intralogistics are handled better.”

MADE IN GERMANY

Full Service Provider

Eurotec started as a distributor, before adding its manufacturing capabilities. Now the company sees itself as a Full Service Provider. “We can handle a project from the fastening material side up to the consulting on-site if needed, which has enabled the business to grow and allowed us to really integrate with our clients,” states Markus. “The customers really connect with us and know we can support them at every level of the project.” This includes starting from the design, where Eurotec has a dedicated technical team in-house that can work on CAD drawings and realise clients wishes. In addition, there are software solutions such as the deck estimation software or its ECS (Eurotec Calculation Software) to estimate even critical connections for timber engineering projects. “The ECS software is kept up to date with the newest products and regulations and covers concrete, timber connections, roofs and cladding, as well as our latest range of fasteners,” mentions Markus. “The user just needs to know the load that is applied to the application. Our software will then show them which fasteners will work and what will be the value taken in loads. They can then optimise their complete construction and visualise it via a 3D image.” “There are so many obstacles when ordering from Asia, and customers are sometimes not aware of the pitfalls. They seem to focus only on the price, but to get to the required quality and a reliable supply is not easy,” adds Joern. “We can combine producing products in Germany with our knowledge and experience of buying in Asia to provide a complete range. We even have an Asian subsidiary that monitors the quality processes at our suppliers, as well as takes care of the sales within Asia. It is also constantly in contact with our partners – asking for samples and discussing drawings. Without this strong connection to the market, and our partners, we wouldn’t source from Asia. Flying out once a year is not the answer.” In addition to its subsidiary in China, Eurotec also looks to include local people within key markets – such as France, the UK and Poland, which enables it to really connect with the market and understand what is happening. “Thanks to our huge stock, good availability of goods, manufacturing capabilities, and sophisticated logistics and shipping partners, we manage to get our goods to any site in the world in the required time frame,” states Markus. “Even our distribution clients are coming to us and asking us for help with their customers. Our service goes hand in hand regardless of the customer and we can only do this thanks to the knowledge and experience within the business.”

Connecting with customers

Another topic Eurotec believes will provide further opportunities in the future is digitalisation. “The human resource at a business is critical, but we are no longer just a human workforce. We need digitalisation – such as our ERP system, eCommerce and even social media – to help us further meet customers’ needs,” mentions Joern. Internally Eurotec is currently uplifting all its processes on a central ERP system, which works across all departments without any third-party interfaces. “This allows us to realise for example web shops or to implement full product information management, so

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we can integrate each employee, and also customers, deeper in the process,” explains Markus. An example of Eurotec’s commitment to digitalisation is its web shop, which can be used by its customers as an embedded web shop if necessary. “This means the client can integrate our shop – with current stock levels and individual prices – into their existing online shop payment methods,” adds Joern. “Once one of their customers’ makes an order on their web shop, it will immediately appear in our ERP order system and get processed like any direct order. This helps speed up the entire process and also guarantees our customers and our customers’ customer are getting the products and service they require.” Whilst Eurotec believes having automation and digitalisation is mandatory as a business within Germany, it is also clear that the human resource is still indispensable. “Whilst production can be handled mainly with machines, tasks like estimation and layout of projects, quality control, product development, application, and preparation of certifications and approvals, as well as customer care, will continue to be handled by our employees as they have the in-depth knowledge and experience of the market, which you cannot get through digitalisation.”

Evolution not revolution

Eurotec underlines that the key to its success is a mixture of supporting its customers; the ability to carry out approvals in-house; its technical team of engineers; as well as developing innovative products. “As a business if you don’t introduce new products then you are going backwards, which is why we are always looking to develop new solutions,” comments Joern. “We believe innovation doesn’t have to be a revolution it can be an evolution. It can involve the production processes or new systems – even the simplest ideas can have a big impact on a business and within the market.” A prime example of Eurotec’s commitment to continuous innovation is its product range for cross laminated timber (CLT) buildings. “The CLT sector is projected to have a growth of €3 billion in the coming years, as the construction sector is starting to focus more on environmentally friendly, sustainable, lightweight buildings,” states Markus. “These types of projects have changed from using normal beams to modular systems with cross laminated timber, which means they don’t use just screws. There are so many forces working on the fasteners, you cannot go with the traditional products. Due to this, we have created complete family items, where we have carried out the relevant tests and approvals, so we can now offer modular CLT parts for multistorey houses.” Markus continues: “We never want to be a company that offers a standard range of fasteners, we want to work on problems and solve them with new solutions. That is why we look to focus on different fields of business or different areas of construction – to see what trends could lead to new opportunities. At Eurotec we set the bar really high, as we want to keep up with our customers’ high expectations. We have achieved a lot when you consider we are only 20 years old. We have developed from ‘two people in a garage’ to a 30,000m 2 business – all whilst ensuring our internal processes enable us to supply high-quality solutions to meet customers’ needs, and still keep the flexibility of the ‘two people in a garage’.” www.eurotec.team

OUR COMPETENCES Timber I Deck and Garden I Roof I Faรงade I Concrete

Production in Germany Over our short 20-year history, we have already become a permanent fixture in the fastening technology sector. Since January 2013, a selected part of the range of timber construction screws has been manufactured on a first machine in Hagen (Germany).

Take advantage of the wide range of products on offer!

An expansion of the machine pool then increased production capacity, allowing us to supply a wide range of items produced in-house.

www.eurotec.team/en/industry

MADE IN GERMANY

LÜLING sets new standards in surface quality with OPTI-S With the newly developed surface quality OPTI-S, Fr. & H. Lüling GmbH & Co KG can now offer its customers the opportunity to opt for a completely new dimension in the surface quality of drawn cold heading steel. This is expressed in the name OPTI-S, which comes from ‘optimal surface’.

he manufacturing processes used to produce an almost faultless surface quality were first developed internally, the success documented with complex testing technology and subsequently verified in practice by the first selected customers. “In the production process used to manufacture OPTI-S, we are currently talking, as far as we are aware, about something that is unique, worldwide,” says Stefan Pelka, project engineer at Lüling. “In addition to the primary goal of producing an almost flawless surface, the economic aspect has also been taken into consideration.” The obligation of suppliers to provide a zero defect guarantee to their customers is not a new requirement, especially in the automotive industry. However, due to the so-called modular systems that are increasingly being used today, faulty parts have an even more serious effect on the quality statistics, as the recall figures of recent years clearly show. “Our top priority has been to create not only a competitive advantage for us but also a significant benefit for the customer. This cost efficiency can be achieved by the use of more streamlined and less costly final testing procedures for the manufactured products, despite a higher material investment price throughout the entire process,” explains Christian von der Crone, managing director at Lüling. “However, if we

manage to do this, the substantial amount of investment spent on the implementation of the project will ultimately be justified.” OPTI-S should therefore be used for products that require an exceptionally high surface quality of the drawn wire as a prerequisite for a subsequent high degree of faultless quality production of the component. “If a customer is interested in using OPTI-S, the first step is to coordinate closely with them. Which parts have a higher failure rate due to non-reclaimable or minor surface flaws? How does the defect pattern leading to the failure occur? How time-consuming and cost intensive is the sorting process? And which quality obligations and promises have to be met by the end user? Once all this information is available in detail, OPTI-S production planning is carried out individually for each product.” The aim of using OPTI-S is to replace the final inspection previously carried out using optoelectronic systems, for example, or personnel and cost-intensive manual sorting, with, at best, only random or largely reduced simplified final inspections. The newly developed production technology is currently available in wire measuring between 6mm – 20mm. www.lueling.com

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MADE IN GERMANY

Heller Premium Tools – quality and innovation For over 170 years, the brand Heller has been inextricably linked with outstanding drilling tools – ‘Made in Germany’. Today, Heller offers drill bits for use in countless materials and as a consequence, the product portfolio now includes chisels, diamond tools, jig and reciprocating saw blades, circular saw blades, bits and oscillating tools.

ith the ‘Made in Germany’ label, Heller Tools GmbH is committed to delivering premium products in order to meet and exceed the highest customer expectations. Since 2014, Heller has been a member of the Serafin Group that has invested heavily in services and production to offer the best customer experience. In addition to the product development, branding, sales, and IT infrastructure, Heller is also focusing on modern and efficient production facilities. Whilst Heller is a German company, it has a global approach. Today, its sales outside Germany account for more than 75% of its total turnover. However, Germany – with its world leading standards – is still Heller’s largest single market and many ideas for innovation come from the work with customers, retailers and end users on construction sites. In the future, Heller will be focusing on its strength as a provider of professional tools and the best services for customers and professional users. This will be visible to the outside world firstly through the newly designed company logo with the brand claim: ‘Premium Tools’, which describes Heller’s self-image. “We are a provider of innovative product solutions used by professional users. Our aim is to supply the user with the best tools across the entire product range of the Heller brand with which they can complete their task simply, quickly and accurately,” says Kay Jungblut, marketing director at Heller. “The segment ‘drill bits’ will remain a core competence of Heller and will be enriched by further product groups. For the future, the company will also extend its existing portfolio with adjacent product segments – offering users clear added value and further strengthening the cooperation with the specialist trade.” An important component of Heller’s DNA is internal and external communication and corporate culture. “As a medium-sized company, we focus on close, cooperative relationships with employees, customers, and business partners, and attach importance to personal contact. This is why we have decided to show this new approach in our communication and are now relaunching the brand,” Jungblut describes. The revised Heller logo is characterised by modernity and clarity in structure, which emphasises the essential components. “It can be used flexibly and is excellently recognisable, especially in digital media. The logo and claim reflects the core message of the brand strategy clearly and in a nutshell, without the need for further explanation: ‘Heller – Premium Tools’.” The logo embodies the most visible change that goes along with Heller’s brand relaunch. The declared goal of the company, which has around 150 highly skilled and experienced employees, is to provide the

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user with quality tools. “Heller products give the professional user the good feeling of working with the best tools for power tools – regardless of which machine or brand is used,” explains Jungblut. The claim to be ‘premium’ is not only limited to the product range. Heller is a close and reliable partner of the specialist trade, which the company supports with a strong range of services. Currently, digital topics are playing an increasingly important role. For example, the Heller website has developed into a central digital platform that offers both the retailer and the user valuable information such as an exclusive application wizard, a knowledge database, Heller TV and a closed retailer area. Heller will continue to expand the digital area in the future and thus pursue the service concept consistently and sustainably. The same applies to the analogue world: Heller supports retailers at the point of sale with individually configurable product presentation systems, pre-assembled modules and attractive secondary placements with high space profitability. In addition, the company is strengthening retail sales with special sales campaigns. In the Heller Training Academy, Heller also educates its customers in the characteristics and use of its products. In summary, the world is becoming more and more digital, which on the one hand results in great challenges. On the other hand, digitisation also offers great potential for success. That is why Heller is already placing a strong focus on digital services today and will continue to expand this area in the future. At the same time, the company continues to support its customers with its proven ‘offline’ offerings, which support sales at the POS in particular. With all these services, leading product performance, and the dedication to continuous investments in a market environment that is predicted to grow in the next years, Heller is looking strong and set-up well for a positive future. www.hellertools.com

Production at Heller today: A fully automatic machining centre to manufacture multi-cutters

Heller TV is a very popular service available on www.hellertools.com, as well as on youtube Retailer support at the point of sale: Heller offers individually configurable product presentation systems

A special service: The Heller training academy

EVENTS CALENDAR

Fastener Fair Turkey Istanbul, Turkey 27 Feb – 29 Feb 2020 www.fastenerfairturkey.com The fastener event for Turkey.

Swissbau

TechniShow

BUDMA - International Construction Fair

ESEF

Poznań, Poland 4 Feb – 7 Feb 2020 www.budma.pl Building technology, equipment and materials.

Utrecht, The Netherlands 17 Mar – 20 Mar 2020 www.esef.nl The meeting place for the Dutch manufacturing industry.

bautec

St. Petersburg Technical Fair

31st Mechanical Components & Materials Technology Expo

wire® Düsseldorf

International Hardware Fair Köln

Empack Utrecht

BYGGERI’20

FEICON BATIMAT

Basel, Switzerland 14 Jan – 18 Jan 2020 www.swissbau.ch National construction fair.

Berlin, Germany 18 Feb – 21 Feb 2020 www.bautec.com Building and construction technology.

Chiba, Japan 26 Feb – 28 Feb 2020 www.japan-mfg.jp/en-gb.html World’s leading B2B trade show for mechanical components/processing technology.

Köln, Germany 1 Mar – 4 Mar 2020 www.eisenwarenmesse.com Global trade fair for the hardware and DIY industry.

Fredericia, Denmark 10 Mar – 13 Mar 2020 www.byggerimessen.dk Scandinavia’s trade fair for construction products, tools and equipment.

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Utrecht, The Netherlands 17 Mar – 20 Mar 2020 www.technishow.nl Benelux’s largest event in the field of production technology.

St. Petersburg, Russia 18 Mar – 20 Mar 2020 www.ptfair.ru Metallurgy, welding, metalworking, tools, materials and machinery exhibition.

Düsseldorf, Germany 30 Mar – 3 Apr 2020 www.wire.de Wire and cable, including fastener manufacturing technology.

Utrecht, The Netherlands 31 Mar – 2 Apr 2020 www.empack.nl The future of packing technology.

São Paulo, Brazil 31 Mar – 3 Apr 2020 www.feicon.com.br Construction industry fair.

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EXHIBITIONS

Small but rather well formed The Confederation of British Metalforming staged its first Fastener Manufacturing Technology & Services Mini-Expo at the National Metalforming Centre in the West Midlands, UK, in mid-October.

he Mini-Expo featured eighteen exhibitors, all providing technologies and services to the fastener and precision component manufacturing sector. These included cold heading and thread rolling machinery, process monitoring, tooling, coatings and threadlocking, forming simulation, lubricants and power management. The event opened to visitors at 10am and ran through until 4pm, with a one hour break, which allowed everyone to network over a light lunch. The focused, time-effective format won praise from exhibitors, able to set-up and breakdown on the day. “The National Metalforming Centre proved an excellent venue for a really focused event,” said CBM Chief Executive Geraldine Bolton. “We are really grateful for the enthusiastic support of the exhibitors, most of whom were CBM associate members.” “Visitors attended from as far as Yorkshire and Kent, as well as the West Midlands, but we would have liked to have seen more take advantage of this unique networking opportunity. Everyone who did attend clearly found it really worthwhile, so we’re sure word will get around the trade that the next CBM Fastener Mini-Expo is definitely not to be missed.” Amongst those who travelled to the event was Tim Garton, managing director of Smith Bullough, who commented: “I found the CBM fastener manufacturing exhibition interesting and worth attending.” CBM aimed to do something unique in the UK by bringing together key suppliers to UK fastener manufacturing into an event very specifically for fastener and precision component manufacturers. That it worked well as a networking event was summed up by one visitor saying it “created a real family feel”. Exhibitors agreed. James Ferrar of Wilde Analysis noted: “Having attended many conferences and exhibitions, I believe that focused and targeted events are the most beneficial.” For the CBM it was also very important to deliver value to its fastener associates, several of which have supported the body and its fastener manufacturing members for many years. CBM’s efforts over the last two years to reenergise its fastener sector have resulted in new members, both manufacturers and associates, joining. The Phillips Screw Company was one such and European Director Stefan Szczurek praised the event: “A good day with the opportunity to network with other exhibitors and to meet potential new clients.” The Mini-Expo built on a series of regular CBM Fastener Sector meetings organised at informative venues around the UK. These included British Steel’s Wire Rod Mill; Dudley College’s ‘Advance’ engineering apprenticeship centre; WMG University of Warwick, a UK centre for autonomous mobility; and most recently, Factory 2050 at the Advanced Manufacturing Research Centre, Sheffield. The CBM told us it is currently collating feedback from Mini-Expo participants in order to plan the next edition, most likely in Autumn 2020. Meanwhile it is organising its next Fastener Sector meeting for early next Spring. News on forthcoming events is posted at thecbm.co.uk which currently also has a page dedicated to the Mini-Expo including photographs and details of all the participating exhibitors. thecbm.co.uk

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EXHIBITIONS

Mixed impressions from first UK Fastener Expo Prysm Group launched its first Fastener Exhibition & Conference at the Birmingham National Exhibition Centre on 11th – 12th September. Pre-show promotion was exuberant, the reality didn’t really live up to it. Some exhibitors came away satisfied, others most definitely not.

he first time show was launched as an extension of events primarily focused on waste management, contamination and flood management. Prysm promised a “complete international showcase of market leading fastener and fixing technologies with 100 exhibitors, 50 speakers and a best in show award”. 100 exhibitors, there were not. The show guide listed less than seventy-five and on the day seven named stands were unoccupied. The largest contingent, around 64% of exhibitors, came from China. Six exhibitors were media or associations, almost certainly exchanges for pre-show promotion. We counted a total of eleven UK exhibitors. Most exhibitors reported that first day visitor traffic had been thin, and it remained so on the second day. Simpson Strong-Tie had the busiest stand and Marketing Manager Kyle Perry was upbeat afterwards. “Our stand being interactive was a real selling point.” Location, en route to the coffee bar and on the cusp of the main show area, also helped as it seemed did Simpson’s own pre-show promotional efforts. Understandably, the company won the organisers’ ‘Best in Show Award’. Luca Brancaleoni, export manager at VITAL SpA, told us: “Frankly speaking we did not see a lot of people.” However, he went on: “We have had some good leads, which is what we were looking for.” His overall conclusion: “Positive experience.” Would VITAL rebook? Probably, he said, but only after the BREXIT outcome was clearer. Jackie Luciano, vice-president of New Jersey-based Zago Manufacturing Products, told us: “Unfortunately, I cannot say it was worth participating, considering the cost and expense of flying all the way from the US. The reason mostly was because there was hardly any traffic/visitors; we expected much more traffic than we got.” Sertel Screw described the event as “not bad considering it is a first show” and said they would rebook. Zygology, in contrast, described the show as very poor with no intention of coming back. Turkish nut manufacturer,

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Som Civata, said they had not really made any connections in their target automotive market. Bond-It said: “Quiet yesterday, not much good. However, we gained a couple of contacts that might pay for the stand,” which they revealed had been booked late at a heavily discounted rate. The Keynote Theatre in the middle of the fastener area was very good but it was not occupied by fifty speakers. The seminar programme included fourteen presentations from eleven speakers. The quality of presentations we saw was very good. Jackie Luciano (pictured above) made a deeply heartfelt plea for engagement with the next generation of manufacturing professionals, debunking many myths about manufacturing, and advocating real commitment to sustainability as a core value to convince next generation engineers. Nimeka de Silva of BUMAX also chose sustainability as a key theme arguing that the resilience of stainless steel materials and their recyclability, met increasing concerns to maximise lifecycles and reduce total life cycle costs. Unfortunately, neither engaged an audience of more than ten people and none of the other seminars we saw were better attended. Prysm Group has announced the next fastener event will be 16th – 17 th September 2020 and says 71% of 2019 exhibitors have already signed up. That would suggest there will again be a preponderance of Chinese exhibitors unless the organisers can, as they clearly did not this time round, convince members of the UK and European fastener industry that the event really is for them.

EXHIBITIONS

Exhibitors get behind Fastener Fair Turkey Driven by positive market outlook, over 120 exhibitors have booked their space at Fastener Fair Turkey 2020, the 5th international exhibition for fastener and fixing technology.

he international fair will take place from 27th – 29th February 2020 in hall 12 at the Tüyap Exhibition Centre in Istanbul, providing a great networking opportunity for buyers and sellers in the industry. More than 120 exhibitors will visit Fastener Fair Turkey from eight countries including Turkey, France, Germany, Italy, Iran, China, Taiwan and the USA, and space is still available. Exhibitors include Turkish firm NORM Civata and Tekelioğlu Civata, both leading manufacturers of nuts and bolts, and Cetin Civata, which markets screws, bolts, studs and other fasteners. Also exhibiting will be Kardemir, a Turkish steel producer. Many foreign companies are exhibiting in 2020 too, notably Berardi from Italy, a supplier of both custom and standard screws and bolts, as well as Reinhardt GmbH from Germany, a market leader of dip spin coating equipment. Another exhibitor is NOF Metal coatings, a specialist in zinc flake anti-corrosion coatings, and part of the Japanese chemical group NOF Corporation. Magni from the USA will also showcase its anti-corrosion coatings. “With such a wide range of exhibitors, this unique fair attracts trade visitors from the automotive, agricultural, hardware, construction and civil engineering sectors, all being major users of fasteners. As many as 2,900 visitors from 48 countries were seen at the 2018 edition, and we expect numbers to rise in 2020. They included global players such as car manufacturers Ford and Toyota, as well as the Turkish Airlines and State Railways,” said Olivia Griscelli, exhibition director of Fastener Fair Turkey, on behalf of the organisers Mack Brooks Exhibitions Ltd. Turkish industrial fastener sales are set to climb by as much as 26.4% from 2020 to 2025, to reach US$1.34 billion, a study on industrial fasteners by the Freedonia Group shows. This is driven by growth in manufacturing activity, with key automotive manufacturers such as Fiat, Daimler and Ford basing their R&D, design and engineering activities in Turkey. The country is also the sixth largest machinery manufacturer in Europe. www.fastenerfairturkey.com

An international and diverse DIY Boulevard at EISENWARENMESSE The DIY Boulevard of the EISENWARENMESSE – International Hardware Fair Köln, taking place from 1st – 4th March 2020, is enjoying increasing popularity among exhibitors for the third time in a row.

ith under six months to go before the start of the trade fair, the Boulevard is already fully booked, with 62 participating companies, and has been extended to 285m. Compared to 2018, this is an increase of around 20%. In addition to 52 national participants from the ranks of the German Association of Home & Garden Manufacturers (HHG), which will once again serve as a cooperation partner, ten international members of the European Federation of DIY manufacturers (fediyma) will also be taking part for the first time. As part of the new layout, DIY Boulevard 2020 will be located in Hall 11.1. A positive POS shopping experience is essential for retailers. The advantage of displaying merchandise on the DIY

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Boulevard is therefore clear – exhibitors can present products and innovations in a POS-related environment and provide trade visitors with solutions for the authentic presentation of goods. In the past, this presentation format was reserved exclusively for HHG members. However, opening it to international exhibitors who are members of fediyma means the number of participants will increase by almost 25% and trade visitors can expect even greater variety. Spanish companies such as Arregui, Caudal, grupodesa Fasteners and Arco are strongly represented among the international brands. Exhibitors from Belgium and Italy, such as Ledent and Volpato, will also bring fresh ideas to the Boulevard. www.eisenwarenmesse.com

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EXHIBITIONS

Fastener Fair India returns to New Delhi

India’s capital city will once again hosts the nation’s premier international event for fastener and fixing technology, with Fastener Fair India taking place from 8th – 9th May 2020 at the Pragati Maidan Exhibition Centre.

uilding on the success of five editions in Mumbai and two in New Delhi, Fastener Fair India will once again provide excellent networking opportunities to all industry professionals, including distributors, suppliers and engineers. India is one of the fastest growing economies and home to many major fastener markets including automotive, telecoms, energy, rail, domestic appliances and construction. This economic growth is set to drive domestic and international investments in the Indian fastener market. Delhi is the largest commercial centre in northern India and many multinational companies have already established themselves within the region. The region also acts as a hub for the automobile industry. Many major automobile companies have established manufacturing centres in the region, such as Hero MotoCorp Ltd, India Yamaha Motor Private Limited and Maruti Suzuki, one of the oldest passenger car makers in India. Found at the heart of the New Delhi, the Pragati Maidan Exhibition Centre is a world-class venue, which hosts a variety of prestigious national and international exhibitions. The seventh edition of Fastener Fair India was held in Mumbai, from 25th – 26th April 2019, at the Bombay Exhibition Centre. The two day event hosted 199 exhibitors. The majority of exhibitors were India-based companies. However, many exhibitors were non domestic, namely from China, Taiwan, Germany, South Korea, the USA and Singapore. A highly qualified audience of 5,192 was on hand to view a comprehensive range of industrial fasteners and fixings, assembly and installation systems, storage and logistics services, fastener manufacturing technology and construction fixings. The specialised exhibition for the fastener and fixing industry attracted visitors from many key industry sectors, including mechanical engineering, automotive industry and hardware retailing. Distributors, wholesalers and retailers were also in attendance. As in previous years, Fastener Fair India 2019 was co-located with BLECH India 2019. India’s premier exhibition for sheet metal working attracted 159 exhibitors from 15 countries, with 5,017 trade visitors. Sales for Fastener Fair India 2020 have started strongly, with a large percentage of stands already booked. Exhibition Manager Martin Clarke comments: “Companies from both India and the wider world have recognised Fastener Fair India as a must attend event for the industry. India’s buoyant economy mirrors the exhibition’s progress, with the show growing year-on-year.” “With six months to go until the exhibition opens its doors, there is no better time to book your stand at Fastener Fair India 2020. Contact the Fastener Fair India team now to discuss opportunities for your company. Further details can be found on the Fastener Fair India website.” Fastener Fair India will next take place in Mumbai, and return to the Bombay Exhibition Centre, in April 2021. Further information about Fastener Fair India 2021 is available on request, from the organiser.

88 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

EXHIBITIONS

Fastener Fair France adds dedicated aerospace area With global demand for aerospace grade fasteners set to climb at a CAGR of 7.6% until 2024, thanks to a thriving aerospace industry, Fastener Fair France has decided to devote an entire area to the sector at the Paris Expo-Porte de Versailles, in hall 3.2, on 27th – 28th May 2020.

his unique area at Fastener Fair France will provide a great networking opportunity for buyers and sellers in the industry. Export giants such as Airbus, Arconic, Align Aerospace, Dassault Aviation, and Safran visited Fastener Fair France in 2018. The motor, construction and manufacturing industries were well represented too, with manufacturing leaders such as Renault, British Steel and fischer also at Fastener Fair France 2018. “Nearly 100 international exhibitors have already booked stands for 2020, to capitalise on the positive market outlook for industrial fasteners,” said Olivia Griscelli, exhibition director for Fastener Fair France, on behalf of the organisers Mack Brooks Exhibitions. Exhibitors from the fastener and fixing industry for the 2020 edition include BAFA SA, Scell-it ® , RMZ Vertriebsgesellschart mbH, pgb-Europe and S+P France. “Visitors are more willing to invest when they have a unique marketplace to enjoy, with the show once again having the support of the French Association of Fastener Distributors in 2020. Out of the 161 international exhibitors in 2018, 75% received positive business

enquiries. The international fair, the only one in France dedicated to fastener and fixing technologies, provides a great opportunity for exhibitors in the fastener industry to display their latest innovations. The fair comes at a key time, with buyers looking to step up purchases to meet growing demand,” said Olivia Griscelli. Driven by a buoyant aerospace, automotive and construction industry, a 24% rise in the French aerospace grade fastener market over 2020 – 2025 to reach US$1 billion (€900.6 million) is foreseen and a 3% annual increase in industrial fasteners is forecast to total US$2.8 billion, a study on industrial fasteners by the Freedonia Group shows. The French aerospace industry, ranked second after the USA, is France’s largest industrial sector, followed by the automotive industry, both predicted to grow steadily until 2025. The global industrial fastener market is also set to grow by 4% annually to total US$99.5 billion by 2025, the Global Industrial Fasteners Report by Product and Market, 9 th Edition by the Freedonia Group, revealed. www.fastenerfairfrance.com

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France’s exhibition for the Fastener and Fixing Industry

The Fastener and Fixing sector has its appointment in France! Fastener Fair France provides business opportunities for local and international suppliers in one of Europe’s major markets and showcases: • Industrial fasteners and fixings

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EXHIBITIONS

wire® 2020 heading for new exhibitor record With four months to go until the two international number one trade fairs for the wire, cable and tube industries – wire® and Tube® – open their doors at the Düsseldorf exhibition centre, from 30th March – 3rd April 2020, registration figures are already very promising.

rganisers have posted a strong increase in attendance from Turkey, India and Taiwan, already exceeding the final exhibitor numbers of 2018. In addition to this, strong participation from the traditional exhibitor regions Italy, Spain, Germany, Austria, Switzerland and central and eastern Europe points to new record exhibitor figures for next year. “The registration figures for wire® 2020, confirm that our exhibitors refuse to be influenced by global economic fluctuations in this industry,” delights Daniel Ryfisch, deputy director metals and flow technologies at Messe Düsseldorf. wire 2020 presents its technical innovations in exhibition halls 9 to 17 on currently 65,000m2 of net exhibition space. This is an excellent result approximately four months ahead of the trade fair. For the duration of wire 2018 65,222m2 net was rented. Exhibitors display machinery and equipment for wire manufacturing and finishing, process technology tools and auxiliaries, raw materials, glass fibre technologies, special wires and cables, measuring, control equipment and inspection engineering. Mesh welding machines will be located in hall 15, spring making technology and products, as well as fasteners and finished products, follow on from this in halls 16 to 17.

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CONSTRUCTION FIXINGS

Speed of serial fixing with manual precision and safety By Magdalena Grzelak, chief communication manager at Rawlplug What determines the final quality of every investment is the precision and diligence with which each stage of works is performed at the construction site.

ven the largest projects depend on the tiniest details, while the operation of large machinery is complemented by the human effort. Mechanical ‘contractors’ experience no fatigue, and they can continue to work almost without interruptions, but it is the operator who makes sure that multiple elements are ultimately combined to create the whole. Even though it is automated and mechanised to a large extent, the contemporary construction site is good for nothing without human intervention. And so, it is for the operators – the heart and soul of every construction project – for whom we have created the new and improved version of the gas powered nailer for concrete and steel – the 2 nd generation SC40 II from Rawlplug.

Repeatability, speed, precision

Direct fastening systems belong to a highly demanding segment of construction tools. What users truly need is not only the speed and robustness of the machine, but also the precision and ergonomics that only their own skills can provide. This is why we were inspired by the symbiosis of human and machines while designing the 2 nd generation SC40 II, and so the tool has been endowed with the very best of them both. It is the durability, speed and reliability of the machine combined with the precision, ease and intuitiveness of human hands. It is a state of the art high capacity battery that ensures long operating time. It is an improved casing that protects

94 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

the nailer against contamination. It is the direct response to operators’ needs.

Work faster, longer and more efficiently

The SC40 II 2 nd generation gas powered nailer from Rawlplug brings changes for improved key tool parameters. Installation in series requires the possibility to use a cordless tool for the long hours you must often spend repeating the same fixing operation. This is why the new nailer from Rawlplug features a long-life ergonomic lithium-ion battery with 2.5Ah of capacity running on 7.2 voltage, thanks to which you no longer need to interrupt work. What does that mean to an operator? It primarily means extended working time enabling them to perform as many as 8,000 fixing operations without battery charging. The nailer set contains two batteries, which can be easily swapped and used interchangeably – this means as many as 16,000 fixings without having to interrupt work. The new technology also translates into improved stability of the charging and discharging process; elimination of the memory effect that would otherwise exert negative impact on the battery life; as well as better parameters attained under extreme conditions (very low or very high temperatures). Contemporary contractors usually operate under the pressure of time, and this pressure is something the best tools in the market must deal with to minimise maintenance downtime. This is why the new nailer’s great advantage from the perspective of working conditions is the battery charging time reduced to 30 minutes, which takes 2/3 times less than to equivalent products. Compared to the speed of manual hammering of fixings, the installation time has been reduced by as many as 15 times, and so when fixing in series, the savings that can be attained are more than notable.

The new battery model is also of significance to the environmental aspect, which practically means compliance with the latest European regulations on introducing heavy metals contained in older generation batteries into the market. Rawlplug is particularly vigilant about this matter on account of its sustainability policy, which involves specific measures being deployed to reduce the negative environmental impact of our operations. What is more, the 2 nd generation tool has been designed in such a way as to provide the user with maximised control over its condition, hence a number of functions that make it easier to monitor the battery status, which conditions the tool’s readiness to work. Not only does the device feature the battery status indicator, clearly showing the current battery power level, but also works in two energy saving modes. One puts the nailer in the standby mode after 10 minutes in idle, which significantly improves the battery life, while the other proves particularly useful when facing time limitations, as it enables the user to charge the battery as quickly as in two minutes – allowing for up to 200 fixing operations to be performed. It is a perfect solution whenever the job must be completed and the battery is completely flat.

Impeccable precision

The goal we pursued while designing the SC40 II 2 nd generation was to create a tool that every professional would consider worthy of their skills. Therefore, not only was it to be robust, but also accurate – after all, it is the know-how and precision of manufacture that decides the durability, quality and safety of every investment. To create such a device was the important task tackled by Rawlplug engineers, who on top of being great theoreticians are primarily construction practitioners, and who turn the experience acquired at numerous construction sites into products that reflect the needs

of consumers of respective categories of fixings and tools. The project was indeed demanding – its outcome, after all, was supposed to be a piece of equipment that can nearly equal human hands while lacking their imperfections. The first of the many improvements introduced in the new nailer is the perfected setting depth adjustment system. The former stepless control knob has been replaced with a two position mechanism – enabling the user to set the nailing depth in all applications regardless of the substrate type. It ensures high precision adjustment while the tool’s design and operation remain as simple as can be. The intelligible markings on the nailer’s body indicate the effect the user is about to produce by setting the toggle switch in the given position. This puts them in control of the fixing operations to be performed. Is there a better guarantee of their reliability?

Improved design – improved working comfort

In order to make sure users get along even better with the tool, we have perfected its ergonomic characteristics. For increased comfort, we have modified the handle positioning, which significantly improves the overall device stability, consequently increasing the comfort of prolonged handling. This change will particularly be appreciated by operators who work in a vertical position, building floor slabs, for instance. What often turns out to be problematic in longish installation jobs is the nailer’s weight, increasing and accelerating the operator’s fatigue. In response to this problem, the 2 nd generation SC40 II features a newly designed magazine made of plastics, which has significantly

FASTENERANDFIXING.COM 95

improved the tool’s balance. We have also made the magazine shorter, which makes tool handling easier in inaccessible locations. On top of that, we have come up with a completely new and simplified magazine dismantling mechanism, accelerating such activities as removing obstructions or cleaning. All the above modifications have allowed us to reduce the tool’s weight, and so the new generation nailer from Rawlplug weighs only 3.4kg, contributing to the unmatched working comfort and minimised operator fatigue.

Durable, strong, reliable

Cleaning is definitely among the activities that slow down and disturb the sequence of construction work. With a tool such as the nailer, a major problem encountered so far was the risk of the device being clogged with contamination of larger particle size, e.g a base material splinter. In such cases, the necessary disassembly of the device was timely and troublesome. This is why Rawlplug’s engineers were focusing on minimising this risk, and hence the new design, which ensures protection of internal components against dust and larger concrete spalls that may be produced during installation. The device casing has also been designed in such a way as to provide maximum protection against contamination while not compromising the comfort of use, especially in the closest vicinity of walls or columns. Thanks to the perfected structure, the front sections ensure superior protection, which has made it possible to extend the tool’s life by around 40%. It gives us certainty that downtime caused by impurities penetrating the tool’s inner structure can be effectively minimised. The new nailer from Rawlplug requires routine periodical cleaning and inspection only, providing users with an infallible tool for years.

Expertise in service of professionals

The aim we pursued was to make the 2 nd generation SC40 II nailer a tool that combines solutions to all problems one may encounter in direct fastening jobs. The effect of our endeavours has been enclosed in a handy compact case. What hides behind the blue Rawlplug logo is a set composed of the nailer along with two long-life lithium-ion batteries, a quick battery charger, a starter pin set, as well as a protective equipment for operators comprising safety glasses and ear plugs. All details of the nailer are described in a digestible user manual that will allow users to advance to a completely new level of construction works, where manual fixing operations are faster, more accurate and more efficient than ever before. Rawlplug’s new equipment has been designed for use wherever operators are dealing with repeatable manual applications. It proves most useful when working on scaffoldings and floor slabs. Users will find it irreplaceable while fixing drywall framing elements, holders as well as cabling troughs and ducts. It is also suitable for installation of cable and pipe clips, and manages just fine in confined spaces of limited access. The nailer can also be used for the fixing of many other system components, and the wide selection of its fixing accessories will enable operators to install meshes and membranes. The SC40 II 2 nd generation nailer is simply much more than a mere tool like a lot of others – it is expertise in service of professionals. www.rawlplug.co.uk

The operation mode of the 2 nd generation SC40 II in cross sectional drawing

Benefits of 2nd generation SC40 II New power supply solution: 8,000 fixing operations following merely 30 minutes of battery charging.

Quick charging mode: Two minute charging is sufficient for 200 fixings.

Improved protection: Internal components are protected against dust and other contaminants extending the tool’s life by around 40%

96 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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17/10/2019 11:39:14

CONSTRUCTION FIXINGS

Standardisation of post installed fasteners – the ‘magic bullet’? 12 myths and facts on hEN and EAD By Thomas Holland-Letz, Construction Fixings Europe Many members of the European ‘anchor community’ – manufacturers, institutes and TABs – will have been surprised by some statements in the article: ‘CE Marking on post-installed fasteners: Why not a European standard?’ in the September 2019 edition of Fastener + Fixing Magazine.

he standard, which was proposed to CEN/TC 185, will not become a hEN, unless the European Commission issues a standardisation request. Therefore, the proposed standard cannot be used as basis for CE Marking and will be useless for the industry and any work for this standard will be wasted. The ETA route to CE Marking of anchors is a success story. The European anchor manufacturers are worldwide market leaders with the most innovative and reliable products. Compared to other regions, the European anchor industry has the biggest variety of manufacturers including a lot of SMEs, which use ETAs for their innovative products in the same way as bigger companies. ETAs have a good reputation worldwide. Important third countries have taken over the assessment methods from the ETA system, which enables European manufacturers to sell their products in a lot of third countries without additional testing or assessment. Unlike in other countries there has been no major failure of fastening application in Europe, which proves the quality of the ETA product assessment procedures. Should we put this proven and reliable system at risk now by moving to the standardisation of anchors? Let’s check myths and facts on hEN and EADs:

The development of new EADs is done by (mostly big) companies:

No. The decision, if a new EAD is developed to deal with an ETA application is done by EOTA, based on the provisions of the Construction Products Regulation (CPR).

EAD versions are changing frequently, which leads to a waste of money for the update of ETAs:

No. Until today, only one EAD for anchors was updated by citation of a new version in the Official Journal of the European Union.

SMEs will benefit from the standardisation:

No. Experience shows that once a product is standardised, it is more difficult for SMEs to compete against bigger companies and importers. For most of the customers, all standardised products are comparable, and they will decide on the product with the lowest price.

SMEs will have more influence in standardisation:

No. Today, manufacturers of all sizes can influence the EAD content via their European associations, which are present in the EOTA Expert Group Fixings, or in direct contact with a TAB. Under a

98 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

standardisation regime, only the national mirror committees decide on the content of the EN. This would oblige all manufacturers to become a member of their national mirror committee, where they have to convince the other committee members. Bigger manufacturers or importers could dominate the standardisation process by sending representatives of their national subsidies into mirror committees in countries where no manufacturers exist.

Standardisation will prevent the proliferation of EADs:

No. The number of EADs will even increase under a standardisation regime, because the standardisation process is less flexible than the EAD process. According to the CPR, manufacturers can apply for an ETA for products and intended uses (e.g fatigue loads), which are not (fully) covered by a Harmonised European Standard (hEN) and the responsible TAB together with EOTA will develop a new EAD. This will happen also after a conversion of the present EADs into a standard.

Standardisation will lower the costs for CE Marking:

Partly. Under the presumption that the current safety level, as defined by the EADs and the AVCP system as determined by the European Commission will be maintained, the costs for testing, evaluation and third party production control will not change. The only costs that would be saved are the fees for the elaboration and the publication of the ETAs by the TABs. On the other hand, these costs are compensated by the additional value of an official document like an ETA compared to a simple DoP based on a hEN.

Standardisation would be a chance to get rid of “useless” tests and assessments in the EADs:

No. The tests and assessment methods in the EADs have been evaluated and confirmed by the European Commission before the EADs were cited in the Official Journal. Therefore, it is very unlikely that the European Commission would accept the deletion of tests and assessments, when the EADs are converted into an EN. Consequently, the respective proposal to CEN seems to intend a 1:1 conversion of the EAD content into standards.

Mandatory CE Marking based on standards will be a benefit:

No. The intention of the CE Marking under the CPR is only to simplify the marketing of a product in the EU and to treat manufacturers equally. CE Marking is not necessary if an anchor

is designed to meet the national requirements in only a single member state. This can save unnecessary costs. Therefore, CE Marking for anchors should remain voluntary.

ETAs are not intended for customers:

Formally correct, but: For complex products such as anchors, specifiers and end users are still used to work with the ETAs, even six years after the CPR came into force. The ETA gives a lot of additional information, e.g end conditions, under which the performance values are reliable and which have to be taken into account for the design of the fastening.

‘Bilateral’ EADs are not based on research and science:

No. Such a statement undermines the reliability of the whole EAD/ETA system. In fact, each EAD is developed by competent TABs, then circulated among all EOTA members, then adopted by the EOTA Technical Board and finally endorsed by the European Commission, before it is cited in the Official Journal. In each of these steps, the consistency and reliability of the EAD is checked by experts. In several cases, the content of EAD drafts had to be changed based on detailed comments by other TABs or by the European Commission. The same steps apply in cases where a ‘basis’ EAD was developed by an EOTA WG, e.g as conversion of a former ETAG.

Only big manufacturers can develop new EADs:

No. Firstly, the manufacturer applies not for a new EAD, but for an ETA. It is then up to the EOTA and the European Commission to decide if a new EAD has to be developed by EOTA. Secondly,

Think Fixing

there are a number of EADs that were developed based on ETA applications by small companies.

Post installed fasteners are “mature” to be standardised.

No. Just the existence of several EADs for anchors shows that this sector is still very dynamic, regarding innovative products and new intended uses. According to Recital 18 of the CPR, hEN can be developed based on EADs only, “once a sufficient level of technical and scientific expertise on all the relevant aspects is attained”. This condition is not yet fulfilled for the different types of anchors for concrete and masonry.

CFE welcomes any fact-based discussion on the pros and cons of EADs versus standards for post installed fasteners, which should also take into account the experience of European manufacturers, end users, specifiers, and national legislators, with standards for other products compared to their experience with products covered by ETAs. thl@construction-fixings.eu www.construction-fixings.eu

About the author Thomas Holland-Letz is project manager at Construction Fixings Europe (CFE), responsible for technical and legal affairs. CFE represents European anchor manufacturers of all sizes and national associations of anchor manufacturers. The main goals of CFE are to maintain the high reliability of anchor fixings, to level the playing field for European manufacturers independent from their size and to encourage innovation.

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CONSTRUCTION FIXINGS

Famous failures series: Part 2 – hydrogen embrittlement By Ryan Murphy, technical director, Evolution Fasteners (UK) Ltd The march of time thrusts forward and in doing so there is continual development of product standards and manufacturing processes. Quite simply, the construction industry demands more performance from products today than was ever done before – at a cost that is as low as possible.

olts and anchors in particular are a victim of this march and consumers now demand higher grades for increased mechanical performance and greater corrosion protection. The danger that follows is hydrogen embrittlement. Despite being first researched and identified in 1875 by W. H. Johnson (Johnson, 1875), the issues surrounding (and nuances therein) hydrogen embrittlement and hydrogen induced cracking are poorly understood in the construction industry. For the purposes of this article the terms hydrogen embrittlement, hydrogen induced cracking and hydrogen assisted cracking can be used synonymously. In 2013, it was found that catastrophic failure of bolts and anchor rods had occurred on the San Francisco Bay Bridge. Thankfully, in contrast to the failures in my previous article: ‘Famous failures series: Part 1 – stress corrosion cracking’ (Fastener + Fixing Magazine, Issue 118, page 98 – 100), there were no fatalities attributed to the failures. Instead the cost was an economical one; to the tune of US$25 million (Derbeken, 2013). Unfortunately for Caltrans (California Department of Transportation, the owner of the bridge), this was just one of the many controversies that befell the bridge – resulting in accumulated costs of US$86.32 million (California State Auditor, 2018). Despite the huge economical cost and political ramifications of the San Francisco Bay Bridge failure(s), it did provoke Caltrans into undertaking a full investigation: An investigation that yielded incredible engineering insight into the underlying science of hydrogen embrittlement. First of all, we need to understand what hydrogen embrittlement is. According to the American Society for Testing and Materials, it is the permanent loss of ductility of a metal or alloy caused

Internal hydrogen embrittlement can be caused by residual free hydrogen from the manufacturing processes involved in producing the products...” by the presence of hydrogen in combination with stress (ASTM International, 2015). In Figure 1, you can see the jagged pattern left by the fissures created by hydrogen embrittlement in a failed bolt from the San Francisco Bay Bridge. The Caltrans report touches on the fact that there are two main general apropos for the source of hydrogen embrittlement, which are termed as:

1. Internal hydrogen embrittlement

Internal hydrogen embrittlement can be caused by residual free hydrogen from the manufacturing processes involved in producing the products, for example in the steelmaking process where it was pickled and coating process where it was galvanised or electroplated (American Bridge/Fluor Enterprises Inc. 2013). Within this genus there are various failure modes (list is not exhaustive): Internal pressure: Where adsorbed hydrogen species recombine to create hydrogen molecules, which in turn create pressure within the metal grain/lattice. This pressure increases to the point where the metal suffers from decreased ductility and tensile strength (Vergani, et al, 2014). Chemical: Formation of brittle hydrides with the parent alloy allowing crack propagation. Enhanced decohesion: Where the strength of the atomic bonds of the elements present in the alloy are reduced.

Figure 1: Cross section of a bolt showing fast fracture region (left) and progressive hydrogen induced cracking (right) phases of hydrogen embrittlement. ©CALTRANS, 2013

100 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

2. Environmental hydrogen embrittlement

Environmental hydrogen embrittlement can be caused by the external introduction of hydrogen while the bolt or anchor is

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CONSTRUCTION FIXINGS under stress (Jones, 1996). Such environmental conditions can include (but are not limited to) the salinity of air or water vapour, leachates, admixtures, effluent or acidity of rainwater (Gangloff, 1986). In both geneses, there is an unholy trinity of combining ingredients that come together to cause hydrogen embrittlement: Susceptibility: The material itself must be susceptible to hydrogen embrittlement either by its metallurgy or mechanical properties (or both). Stress: The material has to be under a tensile load high enough to cause hydrogen embrittlement. Hydrogen: From the aforementioned internal or environmental sources. Now, we have to dive deeper into each of these ingredients and explore the conditions of each.

Susceptibility

From the engineering perspective, material strength has a first order effect on susceptibility to hydrogen embrittlement (as strength increases, steels become less ductile and less tough). At equal strength, steel that has lower toughness is inherently more brittle and more susceptible to hydrogen embrittlement. Research by Caltrans found that the susceptibility of the steel increases significantly when the hardness of the steel exceeds 39 HRC (American Bridge/ Fluor Enterprises Inc, 2013) and this coincides with the findings of other researchers (Brahimi, 2014).

Stress

The very nature of mechanical fasteners in their normal service conditions means they are subject to tensile load (stress being the force applied on a body distributed per unit area of that body). The research conducted by Caltrans found that susceptibility increased significantly once fasteners were loaded beyond 75% of their ultimate tensile strength (American Bridge/ Fluor Enterprises Inc, 2013). In the event the other two conditions are met, then quite simply, the higher the level of stress; the higher the susceptibility to hydrogen embrittlement.

Hydrogen

We briefly touched on the two geneses of internal hydrogen and environmental hydrogen earlier in this article. The principle source of residual hydrogen inside the material is in reversible trap sites

Figure 2 â&#x20AC;&#x201C; Scanning Electron Micrograph showing intergranular fissures in a bolt which failed through hydrogen embrittlement. ÂŠCALTRANS, 2013

102 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

with high bonding energies where hydrogen is released into the material through galvanising or plating in the up-quench (thermal shock) experienced upon immersion on the molten zinc (Brahimi, 2014). The hydrogen then accumulates at grain boundaries. The amount of hydrogen adsorbed from environmental sources is totally dependent on the source itself as well as the condition and type of coating on the fasteners (as well as the condition of the coating). In the case of fasteners being used in steel sections, which are also galvanised, the galvanic corrosion of the sacrificial zinc coating on the steel generates hydrogen and since the steel is the cathode it is readily adsorbed into the grain (The National Academies of Sciences, Engineering and Medicine, 2018). The end result is hydrogen embrittlement, which is characterised by intergranular fracture between the grains of the steel, this is clearly seen under high magnifications in a scanning electron microscope, as shown in Figure 2. Now that we understand the phenomenon of hydrogen embrittlement, what can we do to mitigate or remove it from fasteners? The answer is not easy and is dependent on the fastener type, the materials the fasteners are made from, the coating applied to the fasteners and the environmental conditions the fasteners are subjected. Ideally coatings that produce a lot of hydrogen as part of their industrial process, or evolve hydrogen in their chemical reactions, should be avoided such as electroplating (cadmium, nickel or zinc), galvanising or titanium nitriding in lieu of techniques that either produce less evolved hydrogen or allow evolved hydrogen to escape (i.e. are not barriers to diffusion of the hydrogen) such as organic dip-spin coatings or oxide conversions (Bhadeshia, 2016), as such coatings allow the product to be baked in ovens to allow the diffusion of hydrogen out of the fasteners. The other mitigating solutions are to use a fastener made of a material that is not susceptible to hydrogen embrittlement, as well as simply designing out the issue at the design stage by keeping stress to a level that allows the fasteners to remain in an elastic state.

References

American Bridge/ Fluor Enterprises, Inc., 2013. Metallurgical analysis of bay bridge broken anchor rods S1-G1 and S2-A6, San Francisco: California Department of Transportation. ASTM International, 2015. Standard terminology relating to hydrogen embrittlement testing. West Conshohocken (Pennsylvania): American Society of Testing and Materials. Bhadeshia, H. K. D. H., 2016. Prevention of hydrogen embrittlement in steels. Iron and Steel Institute of Japan, Issue 56, pp. 24-36. Brahimi, S., 2014. Fundamentals of hydrogen embrittlement in steel fasteners. 1st ed. Montreal: IBECA Technologies Corp.. California State Auditor, 2018. Toll bridge seismic retrofit program, Sacramento: Government of California. Derbeken, J. v., 2013. Bay Bridge fix in place, $25 million later. [Online] Available at: https://www.sfgate.com/default/article/BayBridge-fix-in-place-25-million-later-5076643.php Gangloff, R. P., 1986. A review and analysis of the threshold for hydrogen environment embrittlement of steel. Watertown, United States Army Materials Technology Laboratory. Johnson, W. H., 1875. On some remarkable changes produced in iron and steel by the action of hydrogen and acids. London, The Royal Society Publishing , pp. 168-179. Jones, D. A., 1996. Principles and prevention of corrosion. 2nd ed. Upper Saddle River: Prentice Hall. The National Academies of Sciences, Engineering and Medicine, 2018. High-performance bolting technology for offshore oil and natural gas operations. 1st ed. Washington DC: The National Academies Press. Vergani, L. et al., 2014. Hydrogen effect on fatigue behaviour of a quenched and tempered steel. Procedia Engineering, Volume 74, pp. 468-471.

CONSTRUCTION FIXINGS

Fire resistant adhesives in cladding applications Following the terrible fire that engulfed the Grenfell Tower block in West London, UK, in June 2017, the spotlight has been firmly focused on improving resilience against fire in buildings, as well as developing fire resistant materials used in the construction of buildings and in general manufacturing and engineering applications too.

info@blumorgana.it

he use of adhesives and sealants in bonding cladding, fixing stud partition walls, bonding or sealing dilation joints and other applications, has come under scrutiny in the aftermath of this tragedy and with advancements in adhesive chemistry new products have been brought to market. This includes SafeFix® FR300 from Eurobond Adhesives Ltd, a high-quality and durable one component ‘fire resistant’ MS polymer adhesive. SafeFix FR300 is suitable for fire resistant bonding of all kinds of materials used in construction and general manufacturing industries. It is also chemically resistant, permanently flexible and as a sealant can counteract the spread of fire, smoke or toxic vapours. It has a fire resistance of up to 4 hours and is suitable for the fire resistant adhesion of connection and dilation joints in construction. SafeFix FR300 is also certified for horizontal joints and connections to floor/ceiling with wall, wooden and steel casings and all stud applications. The fire resistance tests conform with EN1366-4 to 240 minutes in horizontal or vertical joints measuring 30mm wide. Fire resistance tests, carried out by the Peutz Laboratory for fire safety, were made for the determination of fire resistance of several linear joints with SafeFix FR300 hybrid sealant in walls with elements of aerated concrete, steel, wood and gypsum. The tests were performed in accordance with European standard EN1366-4:2000+A1:2000 using the standard heat curve. Based on the test performed in accordance with EN1366-4:2000+A1:2010, and the extended application in accordance with EN 15882-4:2012, the system was classified in accordance with EN13501-2:2007+A1:2009. An expert judgement was also made for connecting SafeFix FR300 to a steel El60-construction. The adhesive is not suitable for PE, PP, PC, PMMA, PTFE, soft synthetics, neoprene and bituminous surfaces. SafeFix FR300 is available directly from Eurobond Adhesives Ltd in 290ml cartridges or 600ml foils.

HIGH LOAD CHEMICAL ANCHOR FOR CONCRETE

+24°C

+50°C

+72°C

FLOODED HOLE

+40°C -40°C

+80°C -40°C

+120°C -40°C

SERVICE TEMPERATURE

LOW TEMPERATURES

FIRE RESISTANCE

ETA

1937

w w w . b o s s o n g . c o m

ETA

SEISMIC

REBAR as ANCHOR

ETA - 09/0246

Rebar

Post-Installed Rebar

EAD 330499-01-0601

POST INSTALLED REBAR

EAD 331522-00-0601

1962 ®

ETAG 001 Annex E EOTA TR049

TR049 - C1 C2

Annex E - EOTA TR049

2017 fastening systems

FI XI

ETA

EAD 330499-01-0601

Option 1 - Option 7

ETA - 09/0140

VINYLESTER RESIN STYREN FREE

CALCULATION SOFTWARE

EAD 330087-00-0601

CSTB Document Technique d’Application n° 3/16-857 publié le 25/7/2016

2017

BOSSONG S.p.A. Fastening Systems Zona Industriale 2 - Via E. Fermi, 49/51 24050 GRASSOBBIO (Bergamo) Italy Tel +39 035 3846 011 - Fax +39 035 3846 012 info@bossong.com

APPROVED FOR YOU

E TA A P P ROV E D P RO D U CTS

F IRE R ATED

SEI SMI C

Trutek Fasteners Polska Al. Krakowski 38, Janki, 05-090 Raszyn, Poland. trutek.com.pl

trutekfasteners.eu

CUSTOMER SUPPORT

Part 6 – Metal Nail

PRODUCT SELECTION PROGRAMME

Option 7 Throughbolt – Stainless Steel

Option 1 Throughbolt - Stainless Steel

TESTING & TRAINING

Option 7 Throughbolt – Steel Zinc

TECHNICAL DATA SHEETS

Option 1 Throughbolt with C1 seismic – Steel Zinc

Option1 - Concrete Bolt

Option 7 & part 6 Drop In anchors – Stainless & Steel

CERTIFICATION

CONSTRUCTION FIXINGS

New assessment for fischer FIS EM Plus

The fischer injection mortar FIS EM Plus permanently and safely transfers heavy loads into concrete even under the most extreme of conditions. It has demonstrated its capabilities on record breaking constructions such as the world’s longest sea crossing, China’s ‘Hong Kong–Zhuhai–Macau Bridge’, and the ‘Statue of Unity’ in India, the world’s tallest statue.

new assessment has now certified that the FIS EM Plus has a lifespan of 120 years, which is a unique selling feature on the market. The FIS EM Plus is fischer’s highly reliable bonded anchor for high load-bearing capacity in concrete (C20/25 to C50/60). The injection mortar even provides a reliable hold in earthquake prone areas and has been approved for category C1 and C2 seismic applications and categories A to F in accordance with the ICC-ES. It is also a safe choice for water filled drill holes and in case of fire (R240 fire resistance assessment). The FIS EM Plus has two European Technical Assessments (ETA) that cover fixings in cracked concrete (Option 1) and post-installed rebar connections. ETA – 17/0979 recently extended the working life for fixings in concrete from 50 to 100 years. fischer is therefore among the first in the industry to prove this feature in the assessment. The Stuttgart engineering firm IEA takes things one step further. This approved and notified monitoring and certification centre has certified in an anchoring assessment that the fischer FIS EM Plus has a working life of 120 years. It is the first injection mortar to have ever been awarded such durability. This is a clear advantage for constructions that rely upon a long working life, such as tunnels, reservoir dams and other infrastructure projects. The FIS EM Plus is processed with approved system components such as the fischer threaded rod FIS A – with variable anchorage depths – that can be adapted to the existing load, or the fischer internal threaded anchor RG M I, which is also suitable for temporary and removable fixings. The use of the FIS EM Plus in combination with the fischer rebar anchor FRA is also covered by the ETA. The injection mortar can be used for rebar connections between 8mm and 40mm and enables a bonding depth of up to 2,000mm. Together with the Concrete-Concrete Shear Connector FCC the injection mortar is ideal for the restoration and reinforcement of buildings, bridges and other structures and constructions. As an all-rounder for various building site conditions, the epoxy mortar can also be processed at low temperatures down to -5°C. The FIS EM Plus has also been approved for water filled drill holes. Its optimised formula results in improved load values in concrete, which requires fewer fixing points. The optimised axial and edge spaces enable flexible calculations and fixings placed close to the edge. The FIS EM Plus is also easy to use. There is no need to clean the drill hole when using a hollow drill. The injection mortar can also be used in diamond cut drill holes in concrete, without requiring additional roughing up or associated procedures and tools, while delivering an optimum performance.

Sika acquires Chinese sealants manufacturer Sika has agreed to acquire Crevo-Hengxin, a Chinese manufacturer of silicone sealants and adhesives used in both industry and construction applications.

ith this takeover, Sika is expanding its ‘Target Markets Industry’ and ‘Sealing & Bonding’ presence in China and the Asia-Pacific region, and is gaining additional silicone technology plus a production footprint. Crevo-Hengxin generates sales of CHF 50 million (€45.4 million), with a workforce of 140 employees. Crevo-Hengxin is a family-owned manufacturer of a broad range of silicone products used for façades, fenestration, insulated glass, interior finishing and other sealing and bonding applications. In addition, the company holds a leading position as supplier of silicones for the growing solar industry. Crevo-Hengxin is located in Changshu, 50km north of Suzhou. Operations comprise of a production facility,

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a state of the art R&D centre, a warehouse, and offices. “The outlook for the silicone sealants and adhesive market – and indeed for our business in China – is promising. With the acquisition of Crevo-Hengxin, we will increase our know-how in this key technology, and expand our local production capabilities.” “We can immediately leverage the business potential of the new product lines by exploiting the cross-selling synergies offered by Sika’s extended distribution channels. We look forward to a successful joint future and would like to extend a very warm welcome to all Crevo-Hengxin employees as they join the Sika team,” commented Mike Campion, regional manager Asia-Pacific at Sika.

TGT iS200 - Insulation GAS TOOL

I N S ULATI ON FASTE N IN G - S IMP L IF IED

SAV E T I M E A N D M O N E Y F I X I N S U L AT I O N D I R EC T TO BAS E M AT E R I A L ACC UR AT E A N D CO N S I S T E N T LOW E R O P E R AT I N G FAT I G UE 4 T I ME S FAS T E R T H A N T R A D I T I O N A L M E T H O DS E ASY M A I N T E N A N C E O F TO O L S , L E S S D OW N T I M E

Ceiling Insulation

Exterior Walls

Underfloor Heating

Trutek Fasteners Polska Al. Krakowski 38, Janki, 05-090 Raszyn, Poland. trutek.com.pl

trutekfasteners.eu

Parking Garages

CONSTRUCTION FIXINGS

Recent European Technical Assessments for fixings Following an agreement with the European Organisation of Technical Assessments, here is a list of recent ETAs published in the last two months on the EOTA website. ETA NUMBER

TRADE NAME

COMPANY

ETA NUMBER

t is important to note that existing ETAs may be amended or withdrawn so this list should not be considered definitive. For further information and a full list of valid ETAs visit EOTA’s website. If you have recently received an ETA, and would like to have it included in our table, please email us the full details at editor@fastenerandfixing.com www.eota.eu

TRADE NAME

COMPANY

EAD 330076-00-0604 Metal injection anchors for use in masonry

EAD 330499-00-0601 Bonded fasteners for use in concrete

ETA - 19/0496

ETA - 12/0024

Injection system Chemfix CH+

CHEMFIX PRODUCTS Ltd

ETA - 14/0009

HY 100

HILTI AKTIENGESELLSCHAFT

ETA - 17/0187

SMART S-IRE

PGB-Polska Sp. z o.o

ETA - 19/0516

EV II, Evolution II, EV 2

Selena FM SA

ETA - 19/0518

EV i, Evolution I, EV I

Selena FM SA

ETA - 19/0544

ANCLAJE QUÍMICO NIVEL Bonded anchor

COMAFE S. COOP

EAD 330196-01-0604 Plastic anchors made of virgin or non-virgin material for fixing of ETICS with rendering

ETA - 19/0560

DMT POLYFIX

DROMET Spolka z ograniczona odpowiedzialnoscia Sp.k

ETA - 12/0331

ETA - 19/0561

DMT ECOFIX, ECOFIX WINTER, ECOFIX SUMMER

DROMET Spolka z ograniczona odpowiedzialnoscia Sp.k

Chemfix Injection System PESF Top

CHEMFIX PRODUCTS Ltd

ETA - 19/0515

EV II, Evolution II, EV 2

Selena FM SA

ETA - 19/0517

EV I, Evolution I, EV I

Selena FM SA

ETA - 19/0538

Sigillite PRO SG Poliestere CE

PIGAL SpA

ETA - 19/0540

Illbruck OT135 Résine de scellement

Tremco Illbruck

PPV

F. LESKOVEC, proizvodnja, trgovina in storitve, d.o.o.

EAD 330232-00-0601 Mechanical fasteners for use in concrete

EAD 330087-00-0601 Systems for post-installed rebar connections with mortar

ETA - 03/0008

Sormat through bolts S-KA, S-KAK, S-KAH, S-KAH

SORMAT OY

ETA - 19/0537

ETA - 19/0170

Hilti Concrete Screw Anchor HUS2-H

HILTI AKTIENGESELLSCHAFT

ETAG 020 used as EAD Plastic anchors for multiple use in concrete and masonry used as an EAD

TSIRCO-RES 341G for rebar connection

TSIRCON CO LTD

ETA - 10/0424

FRIULSIDER SpA

ETA - 10/0425

FM-X5

FRIULSIDER SpA

TIMco unveils its most comprehensive catalogue to date TIMco, one of the UK’s largest, independent wholesalers for the construction industry, has launched its new Autumn/Winter 2019/20 catalogue. The new catalogue is its largest and most comprehensive to date and is a further step towards the company becoming a ‘one stop shop’ for all its customers’ product needs.

he 18 th edition of the catalogue features more than 7,000 products with 300 new lines including additions to the core TIMco range of screws, fasteners and fixings, as well as extensions to the Addax Power Tool accessories range including impact driver bit sets and PCD circular saw blades. The new catalogue also includes stainless steel additions to the TIMco classic multipurpose screw range, more than 100 steel hinges in the VETO security and ironmongery range, as well as a new twin slot shelving system. For the first time a first aid range, protective board, as well as a more comprehensive range of adhesives and building chemicals such as TIMco’s fill and fix B1 fire rated PU foam are all being showcased.

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A new range of TIMco Addax abrasives is also showcased, which consists of a wide variety of abrasive rolls, sheets, pads, discs and belts using premium quality abrasive grit. The whole range will be available from November and supported with a 16 page specialist product guide, as well as an introductory video. Simon Midwood, managing director of TIMco, comments: “We’re thrilled to launch our largest catalogue to date, in order to meet the increasing demand for more product lines from our growing customer base, to further develop our strategy of becoming a ‘one stop shop’ for builder’s merchants. The new catalogue features brand new products, as well as extended lines, and we can’t wait to hear what our customers think of them.”

WHY

BUY FROM FAR AWAY WHEN YOU

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CAN BUY ITALIAN

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Via dell’Artigianato, 16-18-20 - 36027 SAN PIETRO DI ROSÀ (VI) - ITALY Tel. 0039.0424.562044 - Fax 0039.0424.564055 E-mail: sipa@sipaitalia.it - E-mail: ordini@sipaitalia.it - Web: www.sipaitalia.it

CONSTRUCTION FIXINGS

Enhanced possibilities in timber construction With a new ETA for HECO-WB® threaded rods and an approval supplement for the HECO-TOPIX® wood screw, HECO Schrauben is expanding the application possibilities of two important products for joints in structural timber construction.

ECO-WB® threaded rods with timber thread now have an ETA (ETA – 19/0129) for joints in load-bearing timber structures. HECO points out that in the future, this will replace the previous general building inspectorate approval and facilitates Europe wide use in safety relevant constructions; as with an ETA, CE Marking is now possible too. Through the ETA, the use of HECO-WB threaded rods has been extended to other applications. In addition to strengthening transverse shear, tensile and compressive reinforcement are now also profitable and possible without the time-consuming application of an adhesive. An additional advantage is that the characteristic tensile strengths could be increased by about 10%. This reduces the use of materials and offers greater freedom in processing. Possible applications include the reinforcement of gable roof girders, in curved girders as well as for penetrations, notches, and transverse connections in structural timber construction. The galvanised, blue passivated threaded rods are available in two diameters – 16mm and 20mm – and with a uniform length of 3,000mm. Before processing, they can be shortened in accordance with the approval. Connections with shorter threaded rod sections are now possible – depending on the diameter, either 128mm or 160mm.

HECO-TOPIX® – ETA expanded

Fast and safe assembly in timber construction without pre-drilling or counterboring, plus a reduced splitting effect – there

are many reasons for using the proven HECO-TOPIX wood screws. Now there is also one more – the European approval of the products has been extended to use in laminated beech veneer lumber and hardwoods. The screws can thus be used more flexibly in a variety of applications in professional wood construction, such as staircase and interior design; structural and general timber construction; as well as in the attachment of rafter mounted insulations or façades. Thanks to the excellent performance parameters of the screws, it was possible to extend the requirements for fastenings owing to the approval supplement. It is thus possible to process the TOPIX screws in all veneer lumbers, including in softwood, at an angle of 0 to 90 degrees (previously 60 to 90 degrees). In hardwood – ash, beech, and oak – as well as in laminated veneer lumber of beech, the screws may be used without pre-drilling in accordance with the approval. Laminated and other beech veneer lumbers have their own thread extraction parameters, which are 2.5 times higher than in softwood. The head passage parameter is twice as high as other materials. Bolting can thus be planned more precisely and economically. The approval extension has already been incorporated in the current version of the HECO-HCS design software. In the wood connection module, the different building materials can be selected. In addition, all approvals and declarations of performance for HECO fasteners are available on the HECO website.

SFS’ lifeline system SFS has installed its unique Soter™ Horizontal Safety Lifeline System on the new visitor centre and gallery, The Weston, on the grounds of Bretton Hall in West Yorkshire, UK. The building has already won four RIBA Yorkshire Awards for its design, which fits with the rural and picturesque surroundings and future vision for the park.

FS Group Fastening Technology Ltd and Templar Roofing Services Ltd collaborated to bring the park’s new building to life, installing SFS’s Soter™ lifeline system into the natural roofline of the building. By installing the Soter lifeline system the architectural design of the building is not compromised, and the low height of the system ensures that it is not obtrusive, blending seamlessly into the structure of the building. “As the roof had been waterproofed already, SFS worked with our operatives to ensure the waterproof integrity of the building was maintained. The whole process went smoothly, and the finished product blended in well with the green and brown roof finishes, while allowing future maintenance of the system to be carried out safely,” said Martin Adwick, managing director at Templar Roofing Services. Having completed several design layouts, SFS recommended a system that minimised the loading back to the

110 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

roof, which was less than 6kN at any given point. The use of the Soter lifeline system will also assist The Weston to maintain the roof and ensure the integrity of the roof for years to come. After being brought on board by Templar Roofing Services, SFS was heavily involved in liaising with the architect and engineer to arrive at a solution that met the Yorkshire Sculpture Park’s health and safety criteria. The system required a secure fixing through the green roof to ensure the roof did not suffer from water ingress. SFS utilised M8 stainless steel gravity toggles to fix the base plate to the roof, which was then weathered by Templar Roofing Services to provide a secure weatherproof installation. “We’re proud to have been a part of the building process of The Weston. Making sure we provide the highest standard of fall safety equipment that blends in with the surroundings is always of utmost importance to us and our customers,” said James Gooder, business manager at SFS Fall Protection.

CONSTRUCTION FIXINGS

Speleologists trust in fischer An international team of speleologists trust in fischer anchors to secure rope fixings for the deepest cave in Europe – in the depths of the Dachstein mountains in upper Austria.

peleologist Alex Hack explains: “Twelve people have already been on the moon. But there are spots on our planet that nobody has ever been.” What is underneath the surface of the earth in caves can‘t be measured and observed by satellites. Axel Hack and his colleagues again and again make their way to this unknown territory and bring to light what is hidden. An area of research that is called ‘speleology’. Since 2012, he has been a member of the Dachstein Caving Expedition, which has been exploring and mapping caves on the plateau of the Dachstein Mountains in Upper Austria for more than 40 years. “More than 850m under the surface, far away from any help, we make our way through the narrowest passages and deep shafts,” Axel Hack continues. “We fight against coldness, hard rock, flash floods and liquid clay.” Numerous vertical lines were interspersed with former river loops that had dug deep into the rock, Axel Hack adds. Crossing these so-called meanders was a power-consuming business. Not to mention the many steep walls, which the speleologists had to climb again and again. “Especially here, where the up and down trails are so vertical and slippery, the cave ropes must be securely anchored. Here, we rely on fischer steel anchors,” says Axel Hack. Therefore, thousands of fischer bolt anchors have already been installed on the expeditions to fix ropes in the caves, such as the FBN II and the FAZ with 8mm in diameter. The breakthrough came in early September 2018 when, after more than ten years of research, the explorers discovered a new passageway to the Hirlatz Cave. As a result, the explored total length of the underground labyrinth grew by 7.2km to over 11km. That makes the Hirlatz Cave the 20 th longest cave in the world. In depth, it ranks ninth with a difference of 1,560m in altitude.

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CONSTRUCTION FIXINGS

Abacus Agents expands Rapierstar range Scotland’s unique specialist distributor to the glass, glazing, door and window sectors – Abacus Agents – has added new Rapierstar high performance fastener options to its range, to help customers upgrade the quality of their manufacture and installation.

erving customers across Scotland and the north of England, the family-owned and managed company has established a loyal and growing customer base since its formation in 1991, driven by its flexibility to go the extra mile to provide whatever a customer requires. Abacus Agents’ range of Rapierstar fasteners for joiners, window and door manufacturers and installers, which already includes StarPVCU window screws, StarTurn® woodscrews – including in stainless steel – and StarPin™ polymer headed pins and nails, is now boosted with StarFix® plug-free frame fixings and additional specialist fixings such as baypole screws. “We’ve built our success on being responsive, flexible and having a narrow range of suppliers. This means we can offer a complete range of products for all areas of the glass and glazing industries, and high-quality fixings that enable our customers to achieve the best results. Our existing range of Rapierstar fasteners has always proved extremely popular, which speaks volumes, so expanding this means customers can take full advantage of what this quality fastener brand offers,” commented Bob Sturrock, managing director of Abacus Agents. “We’re delighted that Abacus Agents has introduced an expanded range of Rapierstar fasteners and look forward to supporting its team and customers to get the most out of our products. There is a strong demand throughout Scotland’s window and door sector for high-quality fixings, so it is fantastic that Abacus Agents are now making it easier for fabricators and installers to access these products,” added Paul McAuley, technical consultant at Rapierstar.

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*SECONDARY OPERATION MACHINES -POINTING -DRILLING -BROACHING

MANUFACTURING TECHNOLOGY

80 years in the name of innovation Founded in 1939, SACMA Group celebrated its 80th anniversary at the historic ‘Temple of Speed’ Autodromo Nazionale di Monza racetrack – located near the city of Monza, north of Milan, Italy.

uests were invited to the National circuit located inside the Royal Park of Monza, the third oldest permanent race track in the world – also the home of the Italian Grand Prix – to tour the most exclusive areas backstage, and also take the wheel of a Ferrari 458 Italia, Ferrari 488 GTB, Lamborghini Gallardo, and Lamborghini Huracan. “We planned this day to celebrate the 80 th anniversary of SACMA and I would like to thank all our customers for their enthusiastic participation. The location was amazing – the famous Monza racing track – where the legend of the speed and motors is ever alive. Speed is getting more and more part of our daily life, at work and beyond. Speed is affecting the actual global market, with easy communication making everything more frantic and fast. Everybody is expecting quick reactions and timed answers,” commented Mr Brigatti, chief commercial officer at SACMA Group. “The ownership of SACMA Group has been very sensitive to that situation and we haven’t hesitated to invest to keep up with the times. In the last five years the Group invested on average €6 million per year, corresponding to about 10% of the total turnover, in new plants, buildings and new activities. We are determined to intensify the production in Italy and to utilise only prime European components. To do that, and to remain competitive, we need cutting edge technology,” continued Mr Brigatti. Mr Brigatti also took this opportunity to announce SACMA’s plans for the upcoming wire® Düsseldorf show. “We know that it is very important to assure the best productivity of machines, but for our customers we want to do more. First of all, this means we must build a lasting collaboration with continuous technical support. Today, besides the usual consulting of parts feasibility, we have established

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inside the technical office a real service of development and design of tools for special parts. The S-Tooling office will be presented officially at the wire show and can count on highly specialised human resources, on simulation software of the latest generation, and a dedicated 3D printer to issue the preview of deformation sequence.” Before guests took part in their ‘speed laps’ they were taken on a recognition shuttle lap driven by a fully trained coach to get to know the track before driving. Throughout the day, guests could also experience alternative driving activities, including a drifting experience in a specially equipped paddock area, and an F1 driving simulator where it was possible to try the driving position and grip the steering wheel of a real single seater F1. During lunch, SACMA president, Valeriano Rampezzotti, gave an empathetic address, reinforcing SACMA’s message as a family owned company, and thanking customers for 80 years of trust. “I feel bound to keep what my grandfather and my father did for SACMA. My aim and responsibility for the future is to make SACMA Group even stronger and more structured and to grant our leadership continuity. My father will always be our guiding light.” “He built SACMA on flexibility, which is the only way to keep up with the continuous changes in our field. He taught us to manage our production according to the needs of a very complex and competitive world. He invested in the future and always trusted SACMA, and we will do the same – driven by the trust you give us day-by-day. We look ahead having always in mind the competence and experience of the past 80 years. Honesty, determination and useful cooperation are the values that led us to our today’s reality.” www.sacmagroup.com

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MANUFACTURING TECHNOLOGY

Thread roller monitoring with Brankamp Thread roller monitoring is usually done with force sensors in the machine frame, the die block or in bolster pieces in front of the setting screws. However, a gap in monitoring of thread rollers exists, if the rolling forces are very low (small or very short screws) or if itâ&#x20AC;&#x2122;s a re-rolling process after hardening.

his situation occurs especially on small thread rollers for micro screws or on bigger machines, which re-roll threads after hardening of the part. For those applications with low or erratic force signals, improved monitoring methods based on a distance measurement between an analogue distance sensor and the head of the screw, during the rolling process, was developed so that the main process failures are detectable. The monitoring method (envelope monitoring) and the monitoring units (Brankamp X series) are the same as they are for force monitoring, but the type of sensor, sensor location, signal signature and set-up procedure are different. It is also possible to combine force and distance monitoring in one unit, so both types of process signal can be evaluated inside the Brankamp system. A lot of rolling failures are caused by a poor introduction process of the part, so in those cases, the part can raise, run down, slide during the rolling process or be introduced at a wrong level. In cases where the part is rolled with a washer, a missing washer can cause the same process failure as the introduction at a wrong level. All these failures can cause a variation of the distance between a distance sensor, which is mounted above the rolling dies and the head of the part when it is passing the sensor position. If the part runs up, the distance reduces and if the parts runs down, the signal increases. In all cases, whether the part slides or gets stuck during the introduction or rolling process, the timing of the distance curve varies and exceeds the envelope, which is expecting a reproducible timing of the rolling process. An additional help to adjust the sensor is a LED indicator on the sensor itself, which shows the operator that the distance between the head of the screw and the sensor is inside the measurement range. If the adjustment is correct, it leads to process signals to inform the operator. www.marposs.com

MANUFACTURING TECHNOLOGY

Automatic double line for blister packing Throughout its 45 year history, Weighpack has evolved from a small workshop manufacturing weighing machines for fasteners, and other hardware products, to a specialist company that designs, manufactures, installs and services complete packaging lines for the hardware industry.

ith a packaging machine programme featuring more than 50 different machines, Weighpack’s portfolio includes automated bin feed systems, vibratory feed hoppers, weighing and counting machines, case packers, palletisers, bag makers, transport conveyors, box formers and closers, and much more. Besides the standard machines, almost all packaging lines are ‘suit to fit’, custom build systems. Their purpose is to offer customers a wide range of high-quality products, with the best quality/price ratio in the market. This was recently true for a fastener supplier in the US, where Weighpack designed and built a blister packaging line to suit its high demands on packaging quality and performance. The US company realised that between the production of its components and the storage and transport, there is another important process – the process of dosing and packaging. It is a specialist field, which is why Weighpack was invited to work out a ‘suit to fit’ solution for the blister packing process of fasteners, from product infeed up to check weighing, sealing and printing, that would provide efficiency and accuracy. As a specialist in the development and production of complete packaging lines for bulk hardware, Weighpack proposed a tailor-made bag packing line. The original request for quotation cited: ‘The design, fabrication, installation and commission of a fully automated and integrated packaging line with a single point of control capable of portioning and placing customer’s product inside the preformed plastic clamshell blisters, resulting in retail ready sealed packaging’. Weighpack has a unique product speciality – processing products with a small volume and a heavy weight. The Weighpack strength is that it can manage the entire process from the initial advice up to

and including service and maintenance. All components in the packaging line of Weighpack have been optimised and integrated. This means that all partial solutions ‘communicate’ with each other and the peripheral equipment. This has many advantages for a trouble-free operation and efficient maintenance. Weighpack was also able to supply the customer with know-how in the field of machine engineering, mechatronics and control technology, both PLC and PC. It resulted in a system that was built up and tested at the Weighpack company’s plant in The Hague, the Netherlands. Weighpack therefore proposed a packaging line configuration, which is capable of packing two products in one blister (duo-packs). It starts at the infeed of the products where the customer empties internal bins in one of the two main storage hoppers. The product flow from the two 1,200kg/2,600lb capacity vibratory hoppers are regulated by special vibratory pre-weigh trays that stream the products to the Z-shape inclined cleated belt conveyors with wave edge to feed the two 14-head combination weighers, which can generate an output of up to 50 blisters per minute.

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The stacked clamshell blisters are automatically destacked by a blister dispenser and fed into a servo drive pocket conveyor. The pocket conveyor is indexing 4 blisters every cycle, presenting 4 boxes simultaneously to the filling point under the two multi-head weighing systems. Before the first product filling station, a paper instruction card is placed on the bottom of the open and empty blisters. The first product filling point is also equipped with an orientation magnet to align longer steel fasteners in the narrow containers. The second weigher and filling point is used for the filling of the randomly placed, secondary products (wall plug, anchors, etc). In the following indexing sequence, the lids of the clamshell blisters are mechanically closed and check weighted. After the quantity check the closed lids receive a 3-dot tamper evident sealing from an ultrasonic sealing unit. The following laser printer completes the packaging cycle by branding the blisters with a production date coding. A formation pusher at the end of the line pushes 4 boxes at the same time to a packing table were the rest of the case packing and palletising is performed manually. www.weighpack.nl

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MANUFACTURING TECHNOLOGY

Smart rolling machines at EMO In order to diversify into new markets, EVIRT Italia Srl exhibited its PLANAR 20 thread rolling machine at this year’s EMO Hannover, which took place from 16th – 21st September 2019.

VIRT’s new generation of smart rolling machines is mainly characterised by a brand new machine frame – designed using CAD 3D systems and stresses simulator software (FEM) to ensure the absolute absence of vibrations in any operating condition. The highest level of stiffness is furthermore essential for every cold and hot rolling process, where the tolerances are more and more strict. “We decided to exhibit at EMO once again to research these new application areas for the metalworking industry. We want to continue to be known as a solution provider and a smart partner for thread rolling technologies. In order to set ourselves apart we must continue to grow our integrity and adapt our technological innovations to different markets, and applications, to become bigger than the rest,” explained Olga Januszek, after sales and marketing at EVIRT Italia. “This year, the show had a better level of visitors, mainly from eastern Europe and Asia, which reflected the exhibitor presence – there was a higher level of Asian exhibitors this year. All in all, the show resulted in some interesting conversations and we met some new clients. It was a good opportunity for us to promote our technologies.

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MANUFACTURING TECHNOLOGY

145 years of innovative metal forming solutions In 1874 National Machinery began with a workforce of just ten. In 2019, the company celebrates its 145th anniversary and has grown to include sales offices, manufacturing facilities, and service centres in 16 different countries worldwide.

ational Machinery LLC has evolved from producing world renowned bolt and nut makers to manufacturing cutting-edge metal forming machinery, technology, and services – supported by holding nearly 800 patents in 18 countries. The company celebrated this milestone with two Open House events, one at the headquarters and main manufacturing facility in Tiffin, Ohio, USA, and another at its sales and service centre in Nürnberg, Germany. Both events hosted global customers and business partners, providing them with a tour of National’s world-class facilities, including allowing access to the company’s never before toured research and development department. Tours included demonstrations of FORMAX® cold forming technology and SMART Machinery thread rolling and pointing technology. Open House guests were also offered the opportunity to attend up to ten different educational seminars covering topics ranging from Industry 4.0; new FORMAX technology; secondary operations such as threading, cleaning, and inspection; along with proactive maintenance and rebuilding. To ensure that each visitor’s time was well spent, in between tours and seminars, guests could review National Machinery’s products and affiliate product booths in a trade show environment, held on-site.

Various entertainment activities also took place, including 40 classic cars on display in Tiffin, and a celebratory beer garden in Nürnberg. The event concluded with a company wide luncheon held in the front lawn of the Tiffin facility. National employees, business partners, and suppliers

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enjoyed a commemorative lunch and speeches by Tiffin city mayor, Aaron Montz, neighboring Heidelberg university president, Rob Huntington, and fourth generation president and CEO of National Machinery, Andrew Kalnow. www.nationalmachinery.com

MANUFACTURING TECHNOLOGY

Automated hot forging line Videx has launched a new fully automated, but with no robots, hot forging line of between six and ten machines, replacing the traditional separate forging presses and trimming operation machines.

ebuted earlier this year at Fastener Fair Stuttgart, the new line comprises of a bar feeder and bar shear, to cut the bars to length – it may also start with wire coils. The line also includes a chamfer machine with optional turning stations; extrusion machine, extruding the chamfered end from major to pitch diameter; induction heating machine; double blow, solid die forging machines with five stations – one feed station, two forging stations and two ejecting stations; cooling conveyor; and a thread rolling machine. The forging machines are available in 300MT, 400MT and 500MT for M20 to M48, M64 and M76 in lengths of 200mm – 1,000mm under head. The head (hex for example) is formed in a closed die and it does not need trimming. The production rate is 4 – 6 parts per minute. The chamfered and extruded bars are fed into the die by a pneumatic piston. The feed dial then indexes the parts to the first forging station, which upsets the parts and breaks the scale. To complete the head shape, parts are then moved to the second forging station. After heading, the parts are ejected to a conveyor that transfers them onto a cooling conveyor – saving intermediate storage and handling – before the parts are placed into the thread rolling machine. The machines are available either independent or as complete lines. “It is the first and only real commercial solution that starts with raw material and ends with a sellable product, making it unique,” comments Videx Machine Engineering Ltd. “As well as being the fastest of its kind, the machine also enables the production of long bolts up to 1,500mm, and simply requires one operator to manage the single panel control.” The high performance accuracy and low maintenance costs of Videx machines has attracted customers from all parts of the world. With its expanding programme, 95% of Videx machines are sold to manufacturers in the USA, Europe, Japan, Australia, South America and other countries. www.videx-machine.com

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MANUFACTURING TECHNOLOGY

Carlo Salvi celebrates its 80th anniversary Carlo Salvi, a benchmark for cold forming headers – producing fasteners for the aeronautic, automotive and electronic sectors, celebrated its 80th anniversary in September.

n occasion to remember the great story of the company from Lecco, Carlo Salvi SpA decided to share the moment with all its employees, their families, former employees, suppliers and partners – organising a party at its premises in Garlate. Welcoming over 300 guests, including the mayor of Garlate, Giuseppe Conti, the Italian presenter and comedian Omar Fantini and the soubrette Giulia Salemi, together with the management of the company – Marco Pizzi, Carlo Salvi CCO, and Germano Pandiani, Carlo Salvi COO – retraced the steps of the Carlo Salvi company history. Other guests on stage included Claudine Hatebur de Calderón, CEO and owner of the company Hatebur and Carlo Salvi, Thomas Christoffel, Carlo Salvi CEO, and Thomas Hiltmann, Carlo Salvi CFO, as well as precious guest Dr Sergio Ziotti, former owner. During the evening the employees also donated a plate to Mrs Hatebur and to Mr Ziotti to demonstrate their gratitude. The institutions that attended the dinner: Lorenza Riva, president of Confindustria, and Sergio Pirovano, president of UPIVEB, expressed their esteem for the company, too. “We wanted to celebrate the past, the present and the future of the company, together with all those who have crossed their lives with Carlo Salvi,” said Marco Pizzi. “From 1939 to today this company has come a long way to be one of the leading companies in the production of headers, selling its products not only in Italy but also abroad and anticipating the actual ecologist trend. Carlo Salvi is now appreciated all over the world for its technology, and its ability to look for new goals and new frontiers. This is thanks to

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the employees that, with their passion, make Carlo Salvi every day more and more famous.” Germano Pandiani added: “With this party we wanted to point out the fact that our gaze is always directed towards the future. A strategy that over the years has characterised the modus operandi of our founder, of all the management, of the company staff and, since 2016, the Hatebur family. A progress that during the last 80 years has brought us to a remarkable production development. The strength of our company and the new products are the ingredients that make this possible.” www.carlosalvi.com

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MANAGEMENT + SYSTEMS

Warehouse robotics for all UK businesses With over 1,000 UK customers and 15,000 end users, businesses of all sizes, industries, and sectors, are currently using OrderWise software – including those in the fastener and fixing industry. Deputy Editor Claire Aldridge visited the UK company’s head office to see how a GB£2 million robotics investment is helping it provide a unique software solution to manage and monitor operations effectively and efficiently.

nitially established from the back of CEO and founder David Hallam’s garage over 30 years ago – the company today employs around 200 people at its impressive purpose-built offices in Lincoln. “When I started OrderWise, I saw a gap in the market. Any stock control and order processing systems were all on main frame computers, which, at the time, cost an absolute fortune for companies to invest in. We’re talking pre-internet when main frame computers took up an entire room. Once the PC was launched, and in time the ability to network was realised – it became clear to me that we could have stock control and order processing systems on PCs. I spent many hours writing OrderWise version 1 – and I knew back then, how many businesses would be able to benefit from it,” explains David. OrderWise is an integrated business management software that brings together the supply chain, order processing, stock management, financials, and distribution processes, into a single application – held on a single database. It can also be scaled to meet the specific requirements of businesses, allowing them to buy only the features needed and grow into the rest later. This helps provide a stable infrastructure that drives better performance and supports growth. “OrderWise can dramatically increase the accuracy, efficiency and cost-effectiveness of all daily processes – whether you’re a wholesaler, distributor, retailer, merchant, web trader, manufacturer or something else entirely,” proudly states David. OrderWise includes dedicated core modules such as stock control, sales order processing, despatch, goods in, purchasing, invoicing,

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reporting, and accounts integration. There is also a variety of additional and specialist features for companies to really personalise and optimise the benefits. These include eCommerce websites for both retail and trade, CRM and marketing, Business Intelligence, advanced warehouse management, mobile WMS devices, KPI dashboards, EDI and sales order mapping, and warehouse robotics – something that OrderWise has invested over GB£2 million in over the last three years. The in-house warehouse robotics division was established in 2016, after studying customers’ picking habits and finding that 50% – 70% of warehouse operator’s time was spent walking between various locations in the warehouse – which simply wasn’t productive. Therefore, after extensive research with robot manufacturers, and investing GB£150,000 in foreign robots, OrderWise began testing procedures and initiated the bought robots in its purpose-built testing centre. “The robots we bought were not passing our simple tests, and quite frankly the difference between the sales literature and reality was quite simply embarrassing. I knew we could do better,” explains David. The decision was then made to design, build and code its own robots. Recruiting both electrical and mechanical engineers to start the design process, OrderWise now has a fully functioning robotics lab where its engineers design circuit boards in-house. “It was important for me to keep the circuit board assembling on-site. Circuit boards control every individual aspect of our robots – movement, battery management, WiFi, safety operations, etc – so I wanted to make sure we had absolute control over the quality of what we produce,” comments David. For the rest of the in-house designed robot, CAD images are sent to a sheet metal supplier where the robot’s chassis, as well as a scissor lift, are both manufactured. “Our knowledge is in controlling the warehouse and in the software element, and in my opinion the two go hand in hand. You can’t just build a robot and get it to do something. We have the knowledge and understanding of what a robot needs to achieve in the warehouse environment to make processes more efficient,” points out David. OrderWise robots have a 36 hour running time and in that time will travel a distance of 15.5km and lift a tonne 800 times. The robots are only part of the solution however – the robots will operate inside a cage and bring specifically designed ‘pods’ carrying stock to fully optimised picking stations. “If you think of a small fully operational warehouse that currently has 10 pickers. We know our robots can reduce these pickers to 3, giving significant cost savings, and will improve stock accuracy considerably,” mentions David. Once the ‘pod’ is at the picking station, a light will shine on the correct bin or product that needs to be picked and loaded onto the pallet – as well as the software screen showing

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“The thing that we found OrderWise are great for, are helping us develop as a joint partner; we don’t look at OrderWise as just a supplier. For us, OrderWise are a partnership, who work very, very closely with us. They come up with some fantastic ideas and they help us to continue to grow.”

MANAGEMENT + SYSTEMS this. If multiple pallets are being picked at the same time, a light will also shine on the correct bin to place the product in to avoid errors. The robots also have built-in scales to make sure the correct product is picked to try and eliminate human error. Once the correct product is picked, the robot will be sent back to the warehouse, and the next pod is already queued up on another robot, waiting for the picker. “We will work together at the conception stage to realise how many robots are needed for maximum efficiency – a picker must never wait for a robot, so enough robots to fulfil picking stations is essential. However, our software is intelligent enough to realise when a picker has spare time, so will change the flow,” comments David. This means one picker could be asked to stock check, or arrange stock for heat mapping – all whilst at their picking station. “We understand that the concept of robotics is an up and coming market in Britain and we need to catch up with the rest of Europe. Amazon has just spent GB£2.5 billion on a fleet of over 150,000 robots. Our aim however is to bring robots and automation to everyday companies and it’s working. Our main obstacle is customers thinking they’re too small for robots – robots are for everyone. Our ROI is approximately 2 years – and we have a number of options for payments,” explains David. Currently OrderWise has four robotics systems in operation and is fully booked for all of 2020. “When we first meet with a customer to discuss robotics, customer requirements tend to be very unique. Our system has to be flexible enough to be customisable to enable our customers to work in the best way they do business – otherwise it simply wouldn’t be feasible,” comments David. “For example, our ‘pods’ operate inside a robot cage – each pod will carry a tonne, so each shelf will take 250kg. It is not possible for most customers to keep all their stock inside the robot cage. We need to imagine what the robots represent is actually the picking phase – so that is around 6/8 weeks worth of stock. We therefore must create a mixture of picking stations and ‘goods-in’ stations where a separate dedicated member of staff can replenish stock in the robotics warehouse from bulk stores.” “The most important thing to point out is that we’re one company that offers it all. We can take a new customer from using a multitude of different systems to OrderWise controlling everything – an e-commerce website, ERP system, accounting and we can automate the warehouse. Nothing is subcontracted out – we work with the customer, to make it as easy as possible every single step of the way.” This working together is apparent in its recognition by numerous regional and national awards in the last couple of years. Last year, OrderWise was named as ‘Business of the Year’ at both Lincolnshire Media Business Awards and Lincolnshire Tech and Innovation Awards. David has also been named ‘Family Business Entrepreneur of the Year’ in the 2019 Natwest Great British Entrepreneur of the Year Awards for the Midlands. Finally, OrderWise has been announced as a finalist in two categories at the Growing Business Awards 2019: the ECI Partners B2B Business of the Year and the Santander Growing Business of the Year. There is a definite enthusiasm and buzz surrounding OrderWise – with the team working to promote its new warehouse robotics technology and bring the concept to all UK businesses. The company has a unique offering – cost savings, efficiency, increased fulfilment, and round the clock support, all from one ERP software provider. “We are a family business competing on a global scale, and to do that we have to be the best,” concludes David. www.orderwise.co.uk

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EFC implements Power BI, linked to SAP and CRM EFC International states that it continues to “redefine the world of distribution” with the recent implementation of Power BI (from Microsoft®), which is linked to its internal SAP operating system and CRM software.

FC has always looked to embrace and implement advanced innovative technology and digital transformation. “Our recent implementation of Power BI provides our executives, engineers, sales managers, salespersons, and business development team, with a powerful business analytics tool that provides real time interactive dashboards – customised to fit our business strategy and performance metrics in all areas of the business,” comments Matt Dudenhoeffer, CEO at EFC. “Our SAP and CRM systems have always been incredibly versatile and useful in enabling customised reports and detailed data for our suppliers and customers at the click of a button, and now we can take that a step further with interactive visualisations through a simple interface.” EFC mentions that it was one of the first distributors in its market space to implement SAP, which was accomplished in the year 2000. “We were ahead of our

largest customers and suppliers, most of whom have subsequently converted to SAP in recent years. We were also an early adopter of CRM. Our entire organisation across the globe is integrated and running on these systems, including our recent roll out of Power BI,” said Tom Mansholt, vice-president of operations. EFC International is an ISO 9001:2015 certified, premier global provider of speciality engineered fasteners including plastic injection moulded parts, spring steel stamped fasteners, hose clamps, panel fasteners, routing components and a vast breadth of numerous other engineered components. EFC services the market through regional field engineers, customer service departments and warehouses located in each region, enabling customers to receive local support and supply. www.efc-intl.com

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MANAGEMENT + SYSTEMS

Smart warehousing – how it benefits a business Here abas Software GmbH looks at how smart warehousing can position a business to optimise the supply chain and give the tools needed to employ efficiency focused strategies such as ‘just in time’ inventory management.

arehouse operations are the bedrock of manufacturing processes. Managing the supply chain and delivering inventory to production teams on time are critical to keeping teams on schedule and getting goods out to customers in a timely fashion. However, the warehouse isn’t simply a cost centre that is necessary for doing business. Instead, it is a place where companies can create value by implementing modern digital technologies, and smart warehouse strategies can empower organisations to unleash the full potential of their warehousing and fulfilment operations. Three positive changes smart warehousing systems allow users to accomplish are: Improving data accuracy and efficiency with smart warehousing; getting creative about storage; and taking advantage of robotics.

Improve data accuracy and efficiency

Data quality is critical in creating value from the warehouse. The faster and more accurately users can log inventory data and communicate updates to stakeholders, the more opportunity there is to use that information across various parts of the business. For example, streamlining cycle counts reduces the amount of time workers spend manually tabulating inventory levels, freeing those employees to spend more time communicating those updates to purchasing officers and similar stakeholders who use those counts to make business decisions. The problem is that doing work faster often leads to more human errors. Smart warehousing technologies overcome this in a few key ways. These include barcoding solutions that make it easier to electronically log assets in the warehouse without manual data entry; RFID enabled solutions that provide hands-free data logging, such as with network connected goggles or headsets, enhancing efficiency while promoting safety; and sensors and monitoring devices that track items on shelves and can also provide automatic updates. For example, smart scales can track the weight of goods on a shelf and alert a worker when it falls below a threshold based on the expected weight of items stored there. These types of solutions provide faster warehouse operations while improving data quality and accuracy by reducing the potential for human error. They are heavily dependent on smart warehouse solutions – they blend always connected data collection tools with warehouse management systems that log, organise and communicate data to relevant users.

Get creative about storage

Traditionally, warehouses have been highly segregated from the rest of the business, with specialised processes and storage methods designed to keep assets organised. While this is still mostly the case, many businesses are starting to experiment with creative strategies that involve storing more inventory in alternate locations and reducing the number of excess assets being stored in the warehouse. These tactics come together to form the idea of ‘just in time’ inventory management, a practice that depends on the smart warehouse and delivers significant value for the business. In practice, a smart warehouse is defined by deep levels of

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connectivity that spread from supply chain management systems to asset intake, inventory management, purchasing, asset delivery to production teams and vendor management. Connectivity across all of these areas of operations creates deep visibility into inventory levels and orders contextualised around production and budget requirements. When everybody has complete visibility into inventory related operations, organisations can, for all intents and purposes, extend the warehouse’s reach beyond its traditional footprint. Businesses can also create multiple small warehouses to better serve remote workers, such as field services employees who need access to key equipment in a time sensitive way, and store key production assets in close proximity to production lines so employees (or robots) can grab the goods they need to complete a work order without having to submit a picking request to the warehouse. This strengthens production, eliminates waste and drives efficiency.

Take advantage of robotics

Today’s robotics solutions can improve the velocity and accuracy of picking while allowing for safe interactions between humans and robots. For example, automatic guided vehicles can be used to move assets through various parts of the warehouse, working side-by-side with humans or other robots to perform the actual picking. This can mean a user leveraging voice automated order picking to identify a pallet that a robot then comes to pick up and transport to its destination. Alternately, drones can fly around the warehouse scanning items on shelves and telling ground-bound autonomous vehicles where they can find goods they are looking for. All of this can be done while humans complete more value focused tasks, positioning organisations to automate and coordinate operations with greater precision. From sensors and monitoring solutions to specialised devices that let users interact with digital systems in safe ways, smart warehouse systems promote efficiency and drive value opportunities across the business. The warehouse isn’t just a cost centre, it can contribute value and create cost savings through digital solutions that add a layer of intelligence to everyday operations. Enterprise Resource Planning solutions make this possible by providing a data hub for the entire business, connecting warehouse management systems with production, accounting and other teams to ensure all stakeholders have access to the data they need.

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MANAGEMENT + SYSTEMS

Justifying cloud-based WMS Many successful start-ups and growing online retailers offer exceptional customer experiences but struggle to manage their stock effectively. They face the dilemma of introducing warehouse management processes that support responsiveness and competitiveness without being time-consuming, cumbersome and expensive.

ntil recently even the most basic entry level systems were probably beyond the reach of many but the advent of cloud-based solutions offers a different approach. The simplicity and relatively low implementation burdens of applications such as ProSKU, make it far easier to justify the investment and realise a return earlier. Inaccurate stock information and failure to identify where items are located in the warehouse can limit a retailer’s ability to provide customers with stock availability details or fully meet order demands on request. It can also cost money because of wasted time, inefficient processes, poor productivity, failed deliveries, product returns or wasteful corrective actions. Stock levels may be too high – leading to inefficient use of space and hidden cost, or too low – leading to missed opportunities. Retailers facing these and other issues will often benefit from a warehouse management system (WMS). The true cost of inaccurate stock information is often higher than initially apparent, but this means net gains and returns on investment in a new WMS can be bigger and realised more quickly than originally expected. This is just one aspect of using a WMS and not the only justification for doing so. Many retailers ultimately realise many more benefits than expected, rendering the monthly system cost largely irrelevant. A cloud hosted solution with a simple monthly pricing model such as ProSKU supports all essential warehouse stock management functions including receipt and ‘put away’, picking and despatch, stock management, and reporting. It integrates quickly and easily with all popular e-commerce platforms including eBay, Amazon, Woo Commerce, Magento and Shopify, as well as traditional CRM solutions such as Sage.

Profitable warehouse expansion Like all good partnerships, any warehouse expansion requires careful coordination between two industry partners – the customer and the materials handling manufacturer – to ensure Return on Investment (ROI). Here, Dexion, a pan-European provider of storage products and solutions, explains how it works together with customers to achieve a detailed analysis of storage requirements.

t begins with good planning. To start with, it would be wise to forecast, perhaps up to as far as ten years ahead, projecting growth and aspirations. Whether the premises is owned or leased, now would be a good time for management to review current and proposed metrics such as SKUs, pick rates and orders processed. Consider the types of goods handled – are they fast moving or C-type slow movers? If the current operation is largely manual, should automation be considered? If so, when is the ambition to become largely automated? If considering expansion, it’s likely that inventory will be bigger. A company will know whether its old way of ‘doing things’ is unlikely to work anymore if it fails to replenish as quickly and accurately as it knows they should be. In that case, now might be the time to consider automating these processes to avoid future errors. A receiving area will invariably be bigger and taking in more stock. In order to avoid a slowdown, products should be received, verified and sorted as quickly as possible. Again, introducing some automation now or in the future could be a good solution. Any planned investment should be carefully considered and be financially justifiable. Think about creating a good working environment for staff. Solely concentrating on stock placement alone can sideline considerations such as having the right lighting and establishing picking routes that make their jobs easier and more importantly, safer. So, who can companies partner with to achieve all of this? Pick a well established storage industry manufacturer who can provide

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a solid record of success, a portfolio of compatible product solutions and a cradle-to-grave sustainable, safe service solution; a partner who can developed future proofed products that can dovetail neatly into your expansion programme as it progresses. So where does the specification start? Dexion doesn’t just offer general advice and guidance about storage requirements; it goes further to provide practical assistance and advice with a more detailed analysis of storage requirements. Dexion’s own in-house analysis will translate storage needs into a specification report, evaluating all areas of a warehouse, including the layout and storage equipment required; material storage locations; the optimal material handling processes and picking speeds; lifetime costs of the system; and growth strategies and market trends. “We determine your optimum layout, system and process flow to ensure your warehouse is continually optimised. Dexion products are designed to withstand tough environments, and they don’t get much tougher than warehouses and distribution centres. The constant movement of goods, forklift trucks and pallets takes its toll on any storage system. We can also supply you with several accessories to keep both your storage system and employees safe,” explains Dexion. Once a specification is produced, the design and installation process is undertaken by qualified engineers and trained installers. A full follow up service regime can be provided to include rack inspection, health and safety, service and maintenance, together with courses and seminars.

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APPLICATION TECHNOLOGY

A wind-win solution Although it’s not obvious from a distance, wind turbine towers are designed to flex and bend, which helps them dissipate the significant forces being exerted upon them. This flexing and bending, however, had been causing a major North American power company dangerous and expensive repair failures in the bolts that hold up the Yaw and Saddle decks inside the tower.

t was a major problem. The company alone has around 6,000 towers of this design and, in total at all companies, there are up to 35,000 of this type in North America. The wind tower OEM suggested various fixes, mostly putting stronger bolts in the L-angle deck brackets. To do this fix was complex and costly, involving maintenance crews working over shutdowns of 24 hours or more. But still, the failures continued. After struggling with this for several years, a creative engineer at the power company concluded the bolts weren’t the problem; the bracket was. Recognising that a successful solution would most likely involve an articulating joint, he scanned the market for the right parts. Since no ‘off-the-shelf’ piece of hardware was readily available, the engineer approached his local Fastenal store to look for possible equipment that could replace the OEM bracket. Tower assembly

The solution

Deeper discussions between the engineer and Fastenal’s technical experts took place. Eventually, a simple solution based on an articulating joint that is secured with Nord-Lock wedge-locking washers was assembled and installed on two of the company’s wind towers as a test. The Nord-Lock washers are important because they prevent the bolts in the articulating joints from coming loose, holding the decks securely in place during operation, something that previous methods had failed to do. The chosen design allows the decks to move slightly in multiple directions when the tower deforms in the wind.

The result

After studying the condition of the twenty new test brackets, installed for more than a year in the Yaw and Saddle decks in operating wind turbines, no signs of wear had been apparent. Based on these positive results, the power company and Fastenal, supported by Nord-Lock Group, created a simple Deck Bracket Replacement Kit. The kit, which will soon be available for shipment to wind turbine sites for replacement work, consists of five articulating joints and the associated bolts, as well as the Nord-Lock washers. Besides offering a permanent solution to the problem, the articulating joint is also much faster to install, taking around 3 – 4 hours. This solution is positive and beneficial for several reasons, including revenue generation, the safety of personnel, maintenance costs and financial payback over the long run. www.nord-lock.com

Power and control cables Yaw bearing

Yaw deck Drip loop

Access ladder with safety device

Saddle

Cable rack, power cables, or bus assembly, along with control cables

Saddle deck

Lighting

Mid deck

Access bulk head door Access stairs

Control and/or switching Down tower assembly Basement area Foundation

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APPLICATION TECHNOLOGY

Holding it together By Ian Parker, freelancer, ianfliesrussian@aol.com

Last July, the world celebrated the 50th anniversary of the Apollo 11 Moon landing. Although the Apollo Moon missions went on beyond that, to Apollo 17 in December 1972 (Apollo 18 was an Earth orbit link up with the Russians, not a Moon landing), it wasn’t long before people and politicians turned their attention to the cost.

he Apollo programme is said to have cost US$20 billion, and those were 1960s dollars (about US$170 billion today) and so the idea that access to space is hugely expensive took hold. Many fascinating space projects have been proposed, but they were beaten by cost. Perhaps seemingly among the most frivolous is holidaying in space, but it’s now available to the super rich and prices will come down. It seemed highly wasteful to use a rocket only once. Surely a reusable spacecraft would be much cheaper – and so we saw the dawn of the Space Shuttle era with the first flight in 1981. But it wasn’t cheaper. NASA has always been coy about precise Space Shuttle costs for this reason. To describe the Space Shuttle as reusable was stretching the description a bit. The main tank was thrown away on every launch, the boosters had to be pulled apart and rebuilt, and the orbiter and its engines required major servicing after every flight. It was a bit like putting your car in for its yearly service after every journey. The last Shuttle flight was in July 2011.

The Shuttle was described as reusable to keep the funding coming. But the other spacefaring nations stuck with expendable rockets, which had then become economic for launching satellites. Such rockets are still the major part of the launch business today. Even the US satellite launch business had kept is expendable rockets. However, reusability is coming back. But this time, it’s real reusability. Perhaps best known is internet billionaire Elon Musk’s SpaceX. The company is landing rockets under propulsion (just like Apollo 11’s lunar module Eagle, which landed on the Moon) and using them again, to bring prices down.

Is there another way of cutting costs? Space

launch vehicles put only a tiny fraction of their total mass into orbit – one of the reasons satellite launches are expensive. A large part of that mass is propellant, which usually involves a fuel and an oxidiser. But oxygen i s freely available in the atmosphere, so why

The proposed SABRE-powered space launch vehicle is a two-stage-to-orbit (TSTO) system with SABRE powering the reusable first stage, which returns to Earth and lands on a runway

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APPLICATION TECHNOLOGY The SABRE engine could propel air vehicles at Mach 5/6

not use that as much as possible? This idea is not new, but the technology to employ it is only now coming to fruition. For a launch vehicle to have a significant air breathing initial segment in its climb, it needs to do so up to Mach 5 or 6 (Mach 1 is the speed of sound, about 750mph at sea level and 0ºC). The problem is heating – air entering the engine at Mach 5/6 is heated to about 1,000ºC and it cannot be used at this temperature. It will get even hotter on combustion and it will melt engine components. So it has to be cooled – a lot and rapidly; this has been the technological challenge for decades. The answer came out of the UK nuclear industry and now UK company Reaction Engines Ltd is running components for its SABRE power plant (Synergetic Air Breathing Rocket Engine). It is applicable to both hypersonic passenger aircraft and space launch vehicles. The key to SABRE is the pre-cooler, which will cool inlet air from 1,000ºC to sub-zero in a 20th of a second. It consists of micro-fine tubing with walls thinner than a human hair and the heat energy exchange is about the same as a small power station when its running. The super cooled onboard hydrogen will be the coolant, as well as the fuel. But what are the tubes made from and how will they be held together under the onslaught of air at Mach 5/6? Also, what will happen if there’s FOD (foreign object damage)? Any object going into the pre-cooler at that speed is going to make a mess and then there’ll be hydrogen where it hadn’t ought to be. This is a huge challenge to the fastener and fixing industry, as well as the material suppliers. Today, Reaction Engines is understandably unwilling to say how it will deal with these problems, but assures interested parties that it has solutions. One thing is known – air will not go straight into the pre-cooler, but will turn through about 60 degrees and enter sideways in the form of a centrifugal separator. Any FOD should carry straight on and not enter the pre-cooler. This kind of separator is often used in aerospace. It’s quite common on helicopters, for example. In fact, the whole of the SABRE engine will be a challenge to the fastener and fixing industry, which may have to look outside its tried

This is a huge challenge to the fastener and fixing industry.” 144 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

and trusted aerospace solutions. Air breathing at Mach 5/6 could be quite a rough ride. Once the air becomes too thin for combustion, SABRE will switch to an internal oxidiser. However, the vehicle will have saved all the weight of an oxidiser that would have been used to that altitude and that transfers directly to available payload weight. In addition, the SABRE engine allows a horizontal take off, removing the need for a launch pad and gantry. The vehicle will take off just like a conventional airliner. At the Paris Air Show last June, Reaction Engines and Air Liquide S.A signed an agreement for the supply of gases and liquids to the Reaction Engines’ Westcott test facility. The Buckinghamshire site will be a national asset bringing unique capability to support hydrogen test requirements in the UK. When commissioned it will enable Reaction Engines to test critical subsystems along with the core of SABRE, while creating future hydrogen testing capability from the UK. The agreement will see Air Liquide design, build, procure, install and commission a gaseous supply system to fulfil the liquid and gaseous hydrogen and liquid nitrogen requirements for Reaction Engines’ Westcott facility. Air Liquide will act as design authority on this project and will manage the full integration and commissioning of the fully operational system – working with key partners. Mark Thomas, CEO of Reaction Engines Ltd, comments: “This is an exciting milestone in the development of our Westcott test site, bringing us closer to the start of testing of our SABRE engine core. Having already worked in close collaboration with Air Liquide, I’m pleased to be deepening the partnership between our two companies, which will help Reaction Engines deliver an operational test facility.” The company has also announced a collaboration with the French Space Agency, the Centre National d’Etudes Spatiales (CNES), and the UK Space Agency, to work together on a joint study to investigate the impact of air breathing propulsion systems on future space launch architectures. ONERA, the French Aerospace Lab, will also assist. The study, carried out under the 2011 Framework Agreement for Reinforced Cooperation in Space Activities, put in place between CNES, and the UK Space Agency, commenced in 2018 and is due to complete towards the end of this year. CNES has a long and successful history of researching and developing the Ariane launcher family, including the currently operational Ariane 5 version. Together all parties have a mutual interest in future space launch technologies and understanding the impact of using air breathing propulsion systems. The objective of this joint study is to assess and quantify the potential advantages and benefits of air breathing propulsion technology for future European launch architectures. The

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APPLICATION TECHNOLOGY study is framed around a two-stage-to-orbit (TSTO) concept launch from Guiana Space Centre in French Guiana, South America. The first stage of this system employs SABRE propulsion on a horizontally launched and recoverable winged vehicle. The second stage employs conventional rocket propulsion and is designed to be expendable. The study includes: An assessment of mission requirements. Definition and assessment of candidate vehicle architectures that utilise a SABRE propulsion system. A complete analysis of the performance of the system through a mission profile and life. Economic assessment of the launch system and consideration around a roadmap and next steps.

Military aircraft

The UK Ministry of Defence intends to place a GB£10 million contract to develop hypersonic propulsion systems for increased aircraft performance and capability. The Defence Equipment and Support’s Technology Office intends to place a circa 2 year, single sourced contract for a UK programme to undertake design studies, research, development, analysis, and experimentation, relating to high-Mach advanced propulsion systems. The contract will be with Rolls-Royce Plc and its technology partners, BAE Systems and Reaction Engines, and will focus on enabling technologies. Speaking at the 2019 Air and Space Power Conference, the UK’s chief of the air staff, Air Chief Marshal Sir Stephen Hillier, said: “As part of the technologies being developed in parallel with Project Tempest, I am delighted to reveal that in concert with Rolls-Royce, Reaction Engines and BAE Systems, we are developing hypersonic propulsion systems, which will be designed and tested over the next two years, paving the way for the UK to become a centre of excellence in this technology and contribute to meeting future UK defence needs.” A joint industry statement by the companies welcomed the initiative. It says: “Bringing together acknowledged aerospace innovation capability from British companies, highlights the importance of collaboration with our partners and will allow us to focus on developing innovative technologies for increased aircraft performance and capability.” High-Mach, or hypersonic, air systems are of growing worldwide interest for a variety of defence and security applications. The extra speed enables new capabilities, including decreased time to target; improved penetration in contested environments; and the ability to access previously unreachable areas. For a range of defence uses, speeds over Mach 4 are desirable and the ability to bridge the gap between required aircraft speed and propulsion system capability is a key enabler. This programme will address this capability gap by developing a variety of technological options and solutions.

The pre-cooler is the key to the SABRE engine. It contains a huge length of micro-fine tubing, which is a big challenge to materials and fastening techniques Last April, the UK’s National Composites Centre (NCC) announced that Reaction Engines had joined its membership network. The partnership with the NCC will focus on accelerating the company’s research in ceramic matrix composites (CMCs). Lightweight, durable and with superior thermal resistance properties, CMCs will play a critical role in the development of components for the rapidly growing commercial space market. Announcing the partnership, Richard Oldfield, CEO of the NCC, said: “The NCC’s partnership with Reaction Engines reflects our ambition to enable every high-tech industry to access state of the art composite manufacturing technology and technical specialists to accelerate their use of composites. We are looking forward to working with a team that share the NCC’s commitment and drive to turn research innovation into commercially viable components.” Richard Varvill, chief technology officer at Reaction Engines, said: “Reaction Engines has recently joined the National Composites Centre to accelerate its ceramic matrix composites research. This allows us to leverage NCC expertise and assist in the development of a UK supply chain – leading to a supply of prototype components to meet the demands of the SABRE development programme.” It’s likely that CMCs will be vital to the fastening and fixing requirements of the SABRE engine, particularly in the pre-cooler. Reaction Engines says: “We’re the only people in the world with the heat exchanger manufacturing experience to bond thousands of joints in a single operation, and achieve zero leakage. The joints in our pre-cooler modules are hermetically sealed, meaning that the gas that escapes can be measured by the molecule.” The extreme environment will need leading edge materials and fastening systems to keep it all together.

The complete SABRE propulsion system

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APPLICATION TECHNOLOGY

New flow hole forming screw creates new application horizons Several years ago, Arnold Umformtechnik developed its Flowform® fastening solution and established it on the market to meet the needs of an increasing number of metal joining applications. Now the company is introducing the next step in its development.

lowform ® , the flow hole and threadforming screw, facilitates single-side access and fully automated joints. With its polygonal tip geometry, the Flowform screw forms a flow hole and taps a thread. This thread is able to accept a metric screw if it ever needs repair. In Flowform ® Plus – an enhancement to the original Flowform product – the company is now reacting to customers’ increasing specification requirements. While needing to consistently reduce CO2 emissions, the automotive industry is also striving to reduce the weight of its vehicles. Increasingly, thinner and stronger steels or aluminium are being used, and the use of mixed materials is also on the rise. Even with these changed parameters, the screws must also be able to guarantee a reliable fastening. One customer approached the Forchtenberg-based fastener experts with such a request. In short, it needed to improve and enhance Flowform to meet these new requirements.

Lightweight structures require positive weight reductions

“With the original Flowform, the limits on joining steels depended on the thickness of the steel at a maximum of 600 MPa, while with Flowform Plus, the limit is 1,000 Mpa,” said Heiko Miller, development project manager for Flowform Plus at Arnold Umformtechnik. With Flowform Plus the Arnold development team changed the dimensions of the fastener from 5mm diameter with a length of 20mm, to 4mm diameter and a length of 20mm. Depending on the head size and length the original Flowform 5.0 weighs around 4g, while the new Flowform Plus 4.0 weighs around 3g. That represents a 25% weight saving. When you extrapolate this to the total number of screws used in the car body it adds up to quite a lot of weight saved. The weight of 500 original Flowform fasteners per vehicle is around 2kg, while 500 Flowform Plus 4.0 fasteners in a vehicle weigh 1.5kg. That alone saves 500g. Moreover, the Flowform tip geometry has been improved and the heat treatment process adapted, so that fastening performances are almost the same.

Fastening point validation secures the future

So when is the Flowform Plus the appropriate fastener? “Customers are usually pretty specific about what they require for a particular fastening point. Our role is to investigate whether the better solution for the specific application is the Flowform or the Flowform Plus. So, for example, in our metal joining laboratory we carry out feasibility tests, using original materials.” “This is where we determine the strength values of the compound structure, and of course the failure point limits. The joining point investigations go into somewhat more detail. In this case customers have already defined the materials pairing they wish to use. Customers also need us to make a recommendation with specific strength values achieved for the joint,” explained Nadine Schmetzer. Since 2017 Nadine has occupied the position of research and development for metal joining technology, which includes Flowform Plus.

148 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

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APPLICATION TECHNOLOGY Over the years Arnold Umformtechnik has built-up a wealth of knowledge and expertise of such investigations, and customers are delighted to avail themselves of it. The new metal joining laboratory at Dörzbach, part of the research and development section, contains a variety of different test rigs, as well as all the standard plant technologies, including a robot cell for close-to-series trials. 2.61mm

Typical applications for Flowform® Plus

In principle the Flowform Plus has been designed for higher strength steels and thicker metal combinations. “With the use of aluminium components, some joints are now thicker, consisting of several layers. Previously, a three layer fastening meant that the top and centre layers had to be pre-drilled. Now, depending on the joined materials, using Flowform Plus means that thicker material combinations of up to 7.5mm can be joined without pre-drilling,” explained Heiko. This is because the reduced diameter causes less material penetration. So there is a smaller gap between the metals and with the smaller dimension, there is less friction surface. So the tapping torque is lower than for the standard Flowform 5. Since the torque levels generally comes out lower, the fastening can also be tightened to a lower tightening torque. According to Arnold Umformtechnik, the fastening strength is not quite as good as with the Flowform 5, but it is good enough for the application. As far as the fastener itself is concerned, a higher strength can be achieved by selecting a suitable material, matched with the appropriate heat treatment process. With the smaller diameter of the Flowform Plus, and therefore its smaller head diameter, the screw is also suitable for use on narrower flanges. Arnold’s developers gave an example to demonstrate what is possible with Flowform Plus. “We joined a three layer metal join consisting of 2.5mm thick aluminium sheets using the standard and also the new Flowform fastener. The result clearly showed less gap formation with the Flowform Plus. Moreover, the Flowform Plus join was made without pre-drilling. For applications using adhesive, which is the normally the case, by omitting pre-drilling, the adhesive is contained, so cannot escape into the hole,” continued

2.6mm 1.03mm

0.51mm

0.99mm

2.58mm 5.08mm 2.54mm

2.56mm

0.23mm 0.43mm

0.22mm

4.07mm 2.59mm

AFF 4.0 AC300_2.5 AC300_2.5 AC300_2.5 2mm Three layer metal fastening for 2.5mm thick aluminium sheets, joined with Flowform ® Plus Heiko. “Making a join without pre-drilling is much better for process cost-efficiency. Users do not need to install expensive optical technology to check that the screw is centred on the hole during the joining process,” continued Schmetzer. Uses for the new Flowform include aluminium-steel mix car body frames, intensive closed section profiles, single-sided access applications, hybrid fastenings, and battery packs.

Many savings over the entire process

With the smaller head diameter of Flowform Plus it is possible to work with the customer at an early stage in order to adapt the component’s engineering design. For example, flanges can be designed to be narrower, creating a corresponding weight saving. With its lower material penetration, less axial force is required for similar material combinations compared with the standard Flowform. This means that the process work load can be reduced. So robots can be correspondingly smaller. With statically stable robots there is less load on the screw during the joining process. “A further advantage is that users can continue to use existing equipment for the screwdriving process. There’s no need for major conversions,” said Nadine. It is important to the Arnold developers that they create the optimum fastening solution for their customer’s component. Which is why customer service is just as important as liaising with the equipment suppliers. “Early communication with all the parties to the process is ultimately the key to implementing the best and most cost-efficient processes,” explained Heiko.

AFF 5.0 AC300 2.5 AC300 2.5 AC300 2.5 2mm Three layer metal fastening for 2.5mm thick aluminium sheets, joined with the original Flowform ®

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APPLICATION TECHNOLOGY

How was the world’s strongest bolt developed? Here premium stainless steel fastener company BUMAX explains how it drew on Nobel Prize winning technology, which revolutionised how chemists understand solid matter, to develop the world’s strongest bolt.

ith production in central Sweden’s steel belt, BUMAX produces what is now widely known as the strongest fastener in the world. BUMAX® Ultra has proven itself in various highly demanding critical fastener applications around the world – providing optimal safety and reliability where standard fasteners are simply inadequate. BUMAX Ultra typically offers a yield strength of over 1,350 MPa, which is three times that of standard stainless steel Class 70 fasteners (450 MPa) and more than double that of Class 80 fasteners (600 MPa). The fact BUMAX Ultra can handle more than twice the load of a standard stainless steel fastener is a game changer for critical fastener applications, providing enhanced solutions that simply were not available a few years ago. BUMAX capitalised on its own material technology knowledge and that of its premium stainless steel supplier, as well as its advanced manufacturing techniques, to develop the world’s strongest bolt. BUMAX Ultra ensures ultra high strength and good corrosion resistance by drawing on Nobel Prize winning quasicrystalline precipitate technology. Materials Science Professor Dan Shechtman won the 2011 Nobel Prize in Chemistry for his work with quasicrystals, which has fundamentally altered how chemists conceive of solid matter. The BUMAX technique uses strain hardening followed by precipitation hardening, which significantly increases the tensile strength of the stainless steel by ensuring the crystal structure reinforces the material. The entire BUMAX Ultra range of fasteners are made at the BUMAX factory in Åshammar, central Sweden.

The strongest bolt in the world – and it’s stainless

Stainless steel fasteners are often selected for their corrosion resistance properties, however reduced strength has historically been an accepted compromise of using stainless steel rather than carbon steel. BUMAX Ultra has changed all that by providing groundbreaking solutions for highly demanding critical applications. “BUMAX specialises in the development of high strength stainless fastener solutions – to ensure superior corrosion resistance, while exceeding the

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mechanical properties offered by carbon steel, standard stainless products and many high alloy fasteners,” explains Örjan Persson, business development director at BUMAX. “Our unique stainless steel fasteners, such as BUMAX Ultra, have revolutionised the fastener market by far exceeding carbon steel in terms of tensile strength.” Application examples for BUMAX Ultra include: Security lock systems – excellent fatigue properties combined with strength. Aerospace systems – good fatigue, corrosion and strength properties and an alternative to titanium fasteners. High pressure applications – high strength requirements, with space limitations. Pump and valve systems – good fatigue properties when compared to high strength carbon steels. Since its launch in 2014, the BUMAX Ultra range has proven that it is capable of exceeding tensile strengths of between 1,500 MPa to 1,700 MPa on various applications, with good corrosion resistance and an operating range of between -50°C and 400°C. BUMAX Ultra is designed for applications that require ultra high strength combined with high ductility and fatigue resistance. BUMAX Ultra applications include security lock systems, aerospace systems, high pressure applications, fueling systems and semiconductor manufacturing equipment – all with excellent results. BUMAX Ultra fasteners are also increasingly used to replace high strength carbon steel fasteners in critical applications with extreme requirements on strength, ductility and fatigue resistance. The very high strength to weight ratio, in combination with BUMAX Ultra’s good formability and ductility, also make it a cost-effective fastener alternative to other lightweight materials such as titanium. All BUMAX Ultra fasteners are custom-made to meet the requirements of each specific application and can be delivered with different mechanical properties. “BUMAX Ultra is an advanced engineering grade and we provide close technical support for customer projects in order to develop the optimal end solution. Even tensile strength exceeding 1,700 MPa is possible with BUMAX Ultra, together with good corrosion resistance, formability and ductility,” comments Örjan.

Lock manufacturer replaces carbon steel screws with BUMAX® Ultra

A leading European lock and locking system manufacturer originally used a DIN 912, M3 x 4 8.8 carbon steel screw for a critical latch screw. Following breakages that disabled the entire locking mechanism, the manufacturer tested both 10.9 and 12.9 without solving the problem. The manufacturer then fatigue tested BUMAX® Ultra, which survived 500,000 strokes without a single breakage – compared with carbon steel screws that only lasted 10,000 strokes. BUMAX Ultra screws are now a critical lock component that helps avoid lock failure.

APPLICATION TECHNOLOGY

stamping out the impact of theft globally

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Leaf spring in innovative life-saving bicycle airbag In the process of developing the third generation of the groundbreaking airbag helmet Hövding, the company’s product developers contacted Lesjöfors. Together, they created a customised wire form for the activation mechanism and a spring clip that holds the gas generator in place.

övding is a pioneering airbag helmet for cyclists, a Swedish innovation from two young industrial designers in Malmö. In the event of an accident, the airbag is triggered from a collar in just 0.1 seconds. Tests show that the airbag offers cyclists superior protection against head injuries, with Hövding’s airbag technology is proved to be up to eight times safer than a traditional bicycle helmet. So far, more than 185,000 airbags have been sold in 16 countries in Europe and Japan. In the autumn of 2018, Hövding’s development engineers contacted Lesjöfors Banddetaljer AB in Värnamo, Sweden. They needed help and support in the design and material choice for both a wire form for the airbag’s activation mechanism and a spring clip, from the leaf spring range. The leaf spring is required for fixating the gas generator that inflates the airbag in the event of an accident. The challenge was to develop two components that would work well mounting wise and at the same time meet the requirements for strength and retained functionality in different weather conditions and user situations. For example, if the cyclist accidently drops the product on the ground. “At an early stage, we could study the design drawings of the desired functionality of the springs. We immediately saw that the wire form for the activation mechanism could be best manufactured by our factory in Nordmarkshyttan, so we involved them, while the leaf spring was perfect for our operation in Värnamo,” says Johan Gannerud, technical sales at Lesjöfors Banddetaljer. While engineers in Nordmarkshyttan improved the wire form further, a close collaboration process began for developing the leaf spring. The two engineering teams discussed drawings, tried different materials and thicknesses and carried out rigorous testing. A handful of prototypes with different contours, thickness and tensile strength eventually came down to one clip with all the desired characteristics. “Hövding presented an initial drawing with specific design features and functionality of the leaf spring. Lesjöfors was a great speaking partner and we got superior support in our collaboration including flexibility and expertise from prototype and tool makers,” comments Hanna Risén, mechanical design engineer at Hövding. Production of both wire form and leaf spring started in the first half of 2019 and so far, both factories have delivered about 60,000 items. “We are proud to contribute to such an innovative product that saves lives all around the world. This project is also a very good example of how we work together within our group for an optimal solution for the customer,” explains Jan-Eric Nordh, plant manager at Lesjöfors Industrifädrar in Nordmarkshyttan.

Trusted brands

Hex socket screws U130 Strength class 12.9

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APPLICATION TECHNOLOGY

NORMA Group will equip 400,000 cars by 2025 NORMA Group has developed line systems for thermal management of battery units for a leading battery manufacturer and will be installed in the electrically driven passenger cars of a major international automobile manufacturer.

roduction of the line systems will begin in 2020, with some 400,000 electric vehicles to be equipped with NORMA Group systems by 2025. “As an industrial equipment supplier with a strong focus on the automotive sector, our ambition is to play an active role in shaping the growth in the area of electromobility. This order once again illustrates that leading automobile manufacturers are relying on NORMA Group’s development expertise for demanding electromobility projects,” explained Dr Michael Schneider, member of NORMA Group’s management board. The thermal management line systems are used inside the battery packs of the electric vehicles and guarantee the correct operating temperature of the battery cells. In this way, the systems make a significant contribution to the optimal performance of the battery and help increase the range of the vehicles. The service life of the battery is also substantially influenced by the thermal management of the cells. Integrated temperature sensors in the line systems also enable particularly precise control and regulation of the coolant temperature. Battery internal thermal management line systems must meet high design and technical requirements, as battery packs must accommodate as many battery cells as possible in order to achieve the highest possible battery performance. Thanks to their optimal compactness and efficient line routing, NORMA Group’s thermal management systems can be installed inside the battery in a space saving format. To ensure that the batteries function reliably and safely in the long-term, it is also essential the line systems and all connections are absolutely leak-free. In development partnership with the customer, the thermal management line systems were optimised to minimum tolerances. The use of laser welding technology meets the customer’s high requirements for precision, cleanliness and tightness of the connections. This high precision manufacturing method allows for thermoplastic joining elements to be reliably and safely joined to thermoplastic smooth or corrugated pipes. The line systems for thermal management are produced at the NORMA Group plant in Pilica, Poland, where an on-site test laboratory supports rapid product development and continuous quality control.

Small diameter springs enable smaller devices Lee Spring Ltd has always offered springs with relatively high spring rates or workable (maximum) loads. But often, the standard outside diameters were too wide to fit within the intended application assembly requirements, or the lengths too long and bulky. Therefore, Lee Spring has added low index, high pressure compression springs to its catalogue.

his new firm, slender spring design offers a high spring rate in a smaller compression spring diameter, without sacrificing any of the pressure and is ideal for operation in confined spaces. The low index, high pressure compression springs are carefully designed to work in small holes, packed with high load capacities and rated to pressures of 300, 400, 500 and 600 psi for easy reference. High pressure compression springs are designed to provide high resistant forces with a relatively slender diameter spring. A standard spring can only support a certain amount of weight and would need a wider profile to take heavier loads, but a high pressure compression spring is fortified to achieve a higher spring rate (the spring rate refers to how many pounds a spring can be compressed to per inch). This means users can pile on much more weight for the diameter, in comparison to standard compression springs. High pressure compression springs are used in applications that demand small devices requiring firm, but not rigid, slender springs, such as in switches, ball plungers, safety relief valves, quick change tools and vice clamps. Using a high pressure compression spring, rather than a standard compression spring, in these instances will mean the spring lasts longer as it can withstand heavy loads – saving money on maintenance.

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High pressure compression springs from Lee Spring are made from passivated and shotpeened stainless steel, which provides a balance of corrosion resistance, high strength, and toughness – meaning these springs will last even longer, whatever the conditions. They range in size, fitting holes as small as 1/8 inch to 2 inches so they can achieve just as much strength and a comparable spring rate to a much larger and heavier spring, but in a much tighter space. They are available in a range of free lengths, starting at 6.35mm up to 101.6mm.

Top Screw Metal Corp.

ISO 9001:2015

TAPES + ADHESIVES

Afera annual conference 2019 is a resounding success The European Adhesive Tape Association’s (Afera) premier yearly event took place from 9th – 11th October at the Pestana Palace Hotel in Lisbon, Portugal, boasting the highest attendance rate ever; ten intriguing future focused presentations; and numerous networking opportunities.

ocusing on ‘making the tape business future proof’, including its effect on the workforce, business models, supply chains, sales channels, technology, product development, and the application process, the conference provided over 150 tape industry professionals with the opportunity to interact with tape industry leaders, sales and technology drivers and field expert speakers. Attendees came from 15 European countries as well as India, Turkey and the USA, and included delegates from businesses along the entire adhesive tape value chain – tape manufacturers, suppliers (raw materials, machine and packaging), converters, distributors, research institutions, national tape organisations and other international counterparts. “I keep saying it every year, but it is true – this is one of the best annual conferences Afera has ever put on. The event showed that there are a lot of topics and issues moving in the adhesive tape industry, and we were able to harness them for this event. As Afera does, we will continue to build on them,” reports Evert Smit, Afera president and head of R&D at Lohmann GmbH & Co KG. “Year over year, the annual conference increases in quality and value to our members. It is the perfect platform from which ‘competitive colleagues’ can form their opinions, and our participant survey feedback enables us to continue fine tuning the event,” explains Jacques Geijsen, Afera marketing committee chairman and managing director at American Biltrite Inc, EMEA and ABItalia.

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TAPES + ADHESIVES A plethora of buzz topics headed the conference working programme, which took place over two days. “We started and ended on topics involving millennials, going full circle with both positive and negative outlooks. Also, what we all have in common is the future – the opportunities and many considerations of human nature, ethics and technology. Afera delivered the whole package,” comments Bert van Loon, marketing innovation expert and independent strategist, who was one of the masters of ceremonies.

Market trends and data

There is a lot of intelligence on the market of how customers and regions are behaving. Collecting and analysing this optimally may require computing beyond human capacity. Matthias von Schwerdtner, Afera marketing committee member and corporate vice-president of development at tesa SE, presented the bigger picture to the conference, explaining: “The adhesive tape industry globally remains a highly fragmented and heterogeneous market, and growth over the next few years is predicted at between 2% and 5%. Speciality adhesive tapes market growth is linked to expanding electronics and healthcare industries.”

Raw materials

Master of ceremonies Melanie Ott, Afera steering committee member and business manager of tapes and labels at H.B. Fuller, agreed with Mr von Schwerdtner, stating that global growth rates for tapes are moving faster than the economy. For the tape business, there is a slightly reduced volume of adhesive raw materials. “What is key: We are very irrelevant to crude oil output, as only a small portion of this goes into adhesive raw materials. But the tapes business needs this feedstock, such as solvents, acrylic monomers and synthetic rubbers, to make adhesives,” comments Melanie Ott. “Over the last few years, there has been a shift in cracker output from heavy to lightweight materials. Although oil prices should stay stable over the next few months, the world economy is slowing and demand is down. What would happen to our industry if the feedstock became unavailable?” Among other current tech trends, Mr Smit discussed regulatory legislation in Europe, North America, and China, including the increasing importance of the EU Circular Economy Action Plan and individual company sustainability programmes and products. He also warned: “Polymer REACH” is coming. “Regulatory issues are a power around us,” Mr Smit continued. “There’s nothing we can do about it, except to pre-empt it by starting to act on them now, like a predictive maintenance for our own industry.” Why adhesive tape related companies were successful

160 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

over the last 3 or 4 decades is not necessarily the reason they will be thriving 5 years from now. “Making sure our business is future proof is not a simple concept,” explained Mr Smit. “You cannot assume tapes will always be used for bonding. Many great technologies have disappeared very quickly.”

Outside of the conference room

Attendees of the Lisbon conference also enjoyed cocktails in the hotel gardens and dinner in the old stables attached to the hotel on the first night. A gospel choir added to the ambience. On the second day, all participants got to discover Lisbon’s waterfront by GoCar, electric bicycle, Tuk Tuk and speedboat, then had drinks and dinner at Kais Restaurant. During the alternate social day programme, partners were treated exclusively to tours of Lisbon’s historic centre and the Belém district (including the Jerónimos Monastery), painting tiles at the National Tile Museum and a cooking lesson. www.afera.com

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TAPES + ADHESIVES

Resisting high temperatures Master Bond Supreme 121AO is a NASA low outgassing approved epoxy suitable for bonding, sealing and potting applications. Featuring a high glass transition temperature of 200°C – 210°C, it resists temperatures up to 550°F (288°C).

aster Bond points out that this system exhibits an element of toughness and is not as stiff as conventional epoxies that withstand extreme temperatures. Supreme 121AO has a strength profile with a tensile modulus of 750,000 psi to 850,000 psi at room temperature and a compressive strength of 26,000 psi to 28,000 psi. Its thermal conductivity is 4 – 5 BTU•in/(ft2•hr•°F), and it is also electrically non-conductive. Shrinkage upon cure is also exceptionally low. This system not only withstands thermal cycling and mechanical stresses, but also resists many chemicals, including water, oils, fuels, acids and bases. As a result, Supreme 121AO can be used in aerospace, electronic, optoelectronic and OEM applications. This two part epoxy has a mix ratio of 100 to 80 by weight. The viscosity of the mixed compound is 10,000cps – 25,000cps, making it readily pourable for potting and casting. It has a long working life after mixing of 2 – 3 days, for a 100g batch. The recommended cure schedule is 1 – 2 hours at 200°F (93°C) followed by 3 – 4 hours at 250°F (121°C), and then 4 – 6 hours at 300°F (149°C). Additional post curing at 350°F (176°C) for 2 – 4 hours will further enhance product properties.

Total leakage prevention Anaerobic adhesives are the ideal choice to augment the seal or holding force of a mechanically joined assembly. They serve as threadlockers, thread sealants, structural and instant bonders, retaining compounds and flange sealants. To provide an overview of how these products can deliver 100% leakage safety, Henkel has also compiled a new guide.

hen designed into an assembly, these products reduce component inventories; decrease total manufacturing costs; enhance equipment reliability; and minimise aftermarket breakdown and associated warranty problems. Henkel points out that LOCTITE® was the inventor of anaerobic adhesives for engineering tasks and continues to develop the technology to expand its scope of applications. Entitled ‘Adhesive & sealant solutions that stop leaks before they start’, this eight page publication uses graphics to show the wide range of applications that benefit from adhesives. Particular attention is given to a range of fluid processing examples and specific solutions for machinery assembly. The guide also includes a handy chart that compares the pros and cons of common sealing methods.

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New optically clear flexible adhesive for bonding displays Techsil Ltd has launched a new optically clear, low viscosity, UV curable adhesive into the UK market. Manufactured by Panacol, Vitralit® 50004 is a one component acrylic adhesive requiring no mixing and has been designed for bonding display screens and laminating optics.

itralit® 50004 adheres to a variety of substrates including coated glass, PET and other plastics and films. Its low viscosity means that it can fill cavities fast without trapping air. The adhesive cures quickly with very little shrinkage, meaning there is less residual stress between substrates. Bonding of large surfaces or lamination of displays is possible by using Hönle’s LED Spot 100 curing system, which matches to the photo-initiators of Vitralit 50004. The alignment of the LEDs of the Spot 100 ensures high intensity and homogenous light distribution. The LED Spot 100 heads can be mounted together without gaps to match the size of the display to bond. Once cured, Vitralit 50004 is very soft. Thermal stresses between dissimilar substrates are neutralised without causing delamination. Its high degree of flexibility enhances performance through repeated thermal cycles. The cured adhesive is optically clear and non-yellowing, with excellent light transmission. Techsil has expertise in many diverse adhesive applications including UV curing adhesives. The company offers comprehensive customer support from selecting the right adhesive and on-site testing facilities to transitioning to volume production.

mayes warwick quarter page-2018-outlines.pdf

CMY

25/01/2018

10:17

TAPES + ADHESIVES

New biocompatible adhesive for plastics fluoresces orange A new orange fluorescent UV adhesive from Panacol-Elosol GmbH is specially formulated for bonding plastics. Vitralit® 7311 FO is certified according to USP Class VI standards, which makes it the perfect solution for bonding medical devices.

itralit® 7311 FO is a low viscosity, transparent acrylic adhesive that cures under UV or visible light. It offers very high bond strength to many plastics including PC, PVC, PMMA or ABS, and also to materials such as glass and stainless steel. Thanks to its very low viscosity and capillary flow characteristics, Vitralit 7311 FO is suited for bonding large surfaces as well as applications with narrow gaps. Under low intensity black light (365Nm wavelength), Vitralit 7311 FO fluoresces orange. This allows in-line inspection for quality control. The bright fluorescence is highly contrasting with plastics possessing a natural blue fluorescence or colour. Optimum curing results can be achieved with LED curing equipment with a wavelength of 405Nm, especially the Bluepoint LED Eco Point Source Unit from Hönle. The Bluepoint LED Eco can be equipped with both wavelengths, serving both processes. Thanks to modern photo initiators Vitralit 7311 FO can be cured – especially in high volume production – within seconds. Once cured, Vitralit 7311 FO is humidity and alcohol resistant. It has also been tested and certified according to USP Class VI standards. The product is compatible to common sterilisation processes such as autoclaving, gamma radiation, E-Beam or ETO and is well suited for use in the assembly of disposable medical devices. www.panacol.com

Industrial Solutions. Panacol-Elosol GmbH and Dr. Hönle AG

High-tech adhesives and UV curing equipment Panacol offers electrically and thermally conductive adhesives as well as UV curing epoxies and acrylates. These high-tech adhesives ensure reliable bonding of metals, glass and plastics. All Hönle UV and LED-UV curing systems are precisely tailored to the UV-reactive Panacol adhesives, ensuring processreliable system solutions.

www.hoenle.com

www.panacol.com

PRODUCTS + TOOLS

A dependable fastening solution Blind structural fastener technology has come to be an essential part of many modern industrial production processes, due to its cost-effectiveness and versatility in so many applications.

hat is why the Huck® FloorTight®, which Star Fasteners states is the ideal blind fastener for all wood to metal applications, has been specifically designed for use in vehicle flooring manufacturing. However, this is not its only use. “We are seeing it used in quite innovative applications including commercial vehicle trailer internal walls – fastening ply to steel uprights,” comments Dan Starbuck, managing director at Star Fasteners. “In fact, we recently helped specify the FloorTight into a large heavy-duty trailer where the load, due to its awkward size and weight, was buffeting the trailer side making the existing screw heads raise and breakaway, which then snagged and damaged its contents.” “The FloorTight fastener offers superior strength to conventional flooring screws and reduces the number of fasteners required and thereby the number of drilled holes. With various clamp strengths available, it is proving to be a popular fastening solution,” explains Dan. “In plywood and plymetal vehicle floor applications, you need a fastener that’s strong, vibration resistant and watertight. Just as importantly, you want a fastening system that’s designed to reduce installation costs.” The presence of the mandrel accounts for a 60% – 80% increase in load-carrying ability in shear and tensile over conventional non-structural blind fasteners. “Structural blind fasteners can be differentiated from non-structural not only by their overall increased level of strength, but also by the fact their published shear values will be higher than their tensile values.” FloorTight’s large grip range eliminates the guesswork as it accommodates material thickness ranging from 19.1mm to 41.3mm. The fasteners offer high clamp, high-tensile and high shear strength, which helps to eliminate the shifting and buckling of a trailer floor. Unlike ordinary nuts and bolts, the FloorTight fastener is watertight on the blind side, preventing moisture from entering through the body of the installed fastener. “The benefits of a blind fastener are easy to see, installing Huck FloorTight fasteners means the only labour required is one person to drill the hole and install the fastener. It is a one-sided installation process and its self-countersinking feature eliminates the secondary counter boring process in plywood. Across a job it adds up to huge time savings,” mentions Dan. “FloorTight uses the force of the mandrel pulling up from the blindside to form a bulbing footprint, which stops the fastener pulling through and securely clamps the materials, whereas self-threading screws only rely on the thread cut into the steel as their anchor point. The engineer can be sure each FloorTight fastener has been installed correctly every time.” A specialist in the supply and distribution of Huck® fasteners, Star Fasteners works with a diverse range of end users and distributors from across a number of industries including rail, solar, wind power, automotive, marine and the commercial vehicle market. Star Fasteners is also an accredited Huck tool service and repair department. Star’s expert technical knowledge and a large tool hire fleet complements the service. An important aspect of Star Fasteners quality promise is also a well stocked tool room. “As a well established leader in the global Huck fastener distribution network, Star Fasteners is committed to supplying customers with the highest quality and most innovative fastener solutions on the market. Systems are ISO 9001:2015 approved, and accreditation from Alcumus SafeContractor has been achieved for excellence in health and safety in the workplace.”

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UK adhesive specialist opens Frankfurt production facility UK-based adhesive specialist Beardow Adams Ltd, which has its global headquarters and manufacturing plant in Milton Keynes, has opened an additional production facility in Frankfurt, Germany, to better serve the market in mainland Europe and avert any potential economic or supply chain risks associated with BREXIT.

omprising three 2,000m2 production halls, the newly constructed multimillion euro facility will initially focus on hot melt adhesives for the packaging market, including the company’s bio-based offer, which is designed for customers with an interest in boosting sustainability and reducing carbon footprint. For convenience, the purpose-built facility is located alongside Beardow Adams’ existing German subsidiary, but has been established as a separate company: Beardow Adams Hot Melt Werk GmbH – which it says houses one of the largest production lines for hot melt adhesives in mainland Europe. “The idea for our new facility in Frankfurt was to create extra capacity for our fast growing business and, due to the original announcement on BREXIT in 2016, it made sense to locate the extra capacity in central Europe. It will serve solely as a manufacturing facility for our existing sales infrastructure in continental Europe, providing quicker and more efficient product supply. Business functions such as sales and support in mainland Europe will continue as normal from our subsidiaries or distribution partners,” explains Eric Coveney, head of marketing at Beardow Adams. The core range of hot melt adhesives for applications such as packaging cases and cartons are the largest business segment within the Beardow Adams Group. At present, the hot melt range is only manufactured in Milton Keynes (where it will continue) and Charlotte, NC, USA, so having a third production unit not only boosts capacity but provides business continuity by acting as a fall back manufacturing contingency.

PRODUCTS + TOOLS

The fastest auto return tensioner on the market Following several years of development and refinement, Nord-Lock Group is celebrating the launch of the brand new Boltight TSR+ auto return tensioner, which boasts a piston retraction time that is four times faster than its nearest competitor. Making it a must have upgrade across multiple industries.

oltight has been at the forefront of hydraulic bolt tensioning technology for nearly 20 years, consistently raising the bar and setting the standard for fast, efficient bolt tightening. Customers already using Boltight TSR tooling will be pleased to learn that TSR+ tools are compatible with existing TSR products, making this upgrade incredibly simple. Aside from speed and compatibility, there are several other features that set TSR+ apart from other tensioners. Its durability has been a key factor in the design, and extensive in-house tests at full stroke, pressure, have shown that it performs considerably better than the current TSR load cells. Safety has also been optimised with a new safety relief valve preventing seal blow outs and exposure to ejected oil. Add to this Boltight’s trademark surface finish, which improves wear resistance

and guarantees corrosion protection against the harshest elements and it’s clear demand for TSR+ tensioners will be high. “We’re delighted to be launching TSR+. Being the fastest auto return tensioner on the market, we feel confident that existing and new customers will see the benefits of improved bolting times and reliability without compromising on safety. TSR+ will be available from stock to support market expectations and ensure fast delivery,” commented Richard Outram, business development director tensioning at Nord-Lock Group. www.nord-lock.com

VIPA grows to face new challenges With over 120,000 references in stock, VIPA SpA is constantly adding to its products to satisfy requests from several industries including automotive, agricultural, machinery, chemical, and engineering. The company is also committed to expanding its offering for woodworking and has developed SPIDIK1™, a universal structural connection system characterised by a revolutionary six spline head screw, which eliminates the need for additional hardware.

he strength of this product is given by its versatility and speed to be fastened into wood boards and panels. Available in five sizes and three different versions, SPIDIK1™ is designed to be a valuable solution for both end consumers and mass production. As well as this new screw, VIPA is determined to continue investments despite the main European economies, currently facing the effects of a new economic slowdown. The company has recently enlarged the storage facility at its headquarters in Rolo, Italy. The new automated warehouse is equipped with five robot aisles of picking, and embraces the ultimate modern technologies, which have recently been inaugurated during the past few months. The recent upgrade of the plants has further increased VIPA’s warehouse capacity, to 100,000 pallets – spread over an area of approximately 23,500m2, and the whole system is now able to work 24 hours a day, by means of automation. Thanks to the improved technical features of the new plant, such as more precise and sophisticated machineries and the continuous commitment to tweak the internal processes, VIPA is now able to grant lower margins of error related to order management. These relevant improvements are an important incentive for VIPA that aims to become a benchmark of the national and international fastener market. Its next step is to acquire the capacity to manage the orders, from the arrival to the shipment worldwide, within 24 hours. www.vipafasteners.com

168 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

PRODUCTS + TOOLS

Quality products by HellermannTyton HellermannTyton is a manufacturer and supplier of quality products for cable management and network connectivity solutions – many of which are manufactured at the company’s multi million pound factory in Plymouth, UK.

ellermannTyton’s Plymouth site powers the cable management industry and is one of two HellermannTyton factories that produce components for numerous markets, providing and designing cable management solutions. This site is also one of the market leading manufacturing sites for material development and expertise within the insulation, identification and protection industries. The Plymouth factory is set within a 2.5 acre site and features production space, warehousing, shipping docks, as well as R&D labs where products are designed and tested to meet stringent customers’ needs. Over the past decade, HellermannTyton has invested in its Plymouth facility in order to increase the productivity and efficiency of the site. This includes expanding the footprint of the factory and investing in state of the art manufacturing and material compounding machinery. Proud to have a factory in Plymouth, HellermannTyton has grown rapidly over the years by focusing on customer requirements and reducing lead times. Offering bespoke products and materials for numerous clients across various sectors – such as aerospace, defence, rail, medical and automotive – has put HellermannTyton at the forefront of innovation and design. Specifications are also an important part of the work carried out at the Plymouth site, with HellermannTyton holding and maintaining approvals to various qualifications including VG95343, AS85049, TACOM, PAN6480, and LUL. Ric Kynnersley, managing director of HellermannTyton, explains: “The Plymouth factory is crucial to our success, with 4 million components being manufactured every year we don’t just supply one solution, we provide a HellermannTyton solution. As manufacturers, we know what the pain points are within the industry and the production process, which is why we aim to make working with us and our products as simple and easy as possible.”

PRODUCTS + TOOLS

A full range of inserts for round and square tubes Inserts for round and square tubes, which have been designed to solve issues related to the forming of threaded holes inside tubes – by replacing the traditional process of welding nuts yet providing a secure and tight fitting – have now been added to Fixi’s wide range.

ade of special steel, Fixi tube inserts guarantee high-tensile strengths after application thanks to the anchoring function of the spring crowns, which expand once inside the tube, without altering the shape and design of the outside. The range of inserts is available in different sizes to fit all types of tubes, ranging from 11.8mm to 61.5mm for inside diameters of round tubes and from 15.7mm x 15.7mm to 48.8mm x 48.8mm for inside dimensions of square tubes. The thread sizes range from M6 to M10, sufficient for any structural requirement. A key feature of the range is the easy and quick fitting by pressure installation both manually or with automated machines. For both round and square tubes the insert is available with or

without head. The flanged version, in addition to having an aesthetic function by closing the end of the tube, allows the insert to work even under pressure, so it is ideal for applications on table and chair legs. There is also a special ‘simple’ version to fit flanged insert for swivel wheels. Fixi Srl has widened its range of products to become a reference point for new industries thanks to these new tube inserts. As well as being used in the furniture industry in the production of tables, chairs, sofas, beds and lamps, the inserts can be used in products with a tubular structure such as gym equipment, trolleys and strollers. The inserts can also be used in signage and construction structures. www.fixi.it

Huge expansions at Accu

This year Accu Limited – a precision engineering component specialist – has undergone some new investments including adding new products to its extensive range of high precision components, as well as opening two new UK warehouses and extending its offices.

ccu specialises in precision screws, washers, spacers, nuts, hardware, belt and pulley systems, along with many other categories such as precision gears, lead screws, machine tooling, screwdriver sets and metrology tools. Due to popular demand, Accu is now also stocking more plastic versions of its stainless steel components. The new plastic materials include polyamide, nylon and polyvinylidene (hexagon bolts), nylon (wing nuts), RENY (hexalobular pan head screws), and polycarbonate (transparent hexagon nuts). Accu has also expanded its range of rivets and rivet nuts, which now includes snap rivets, blind rivets and corresponding blind rivet guns for fast and convenient panel installations. The range of pipe plugs now includes several new products and Accu also now stocks anti-backlash spur gears and Nord-Lock washers, which provide superior vibration resistance and proven performance as demonstrated by Junker tests. The brand new categories include products such as O-rings, hose clamps, industrial castor wheels, adjustable feet, screw cap covers and other cap covers and suction pads. The product expansion follows on from other developments in the business. In April 2019, Accu opened up two new warehouses and extended its offices in order to support the launch of AccuPro, unlimited express delivery service for UK customers.

172 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

Growermetal adds spherical washers and conical seats Growermetal Srl has added two new articles to its standard production range during 2019 – spherical washers (type C) and conical seats (type D) – both manufactured in compliance with the German standard DIN 6319.

he spherical washer, used in combination with the conical seat, guarantees a safe locking function on non-parallel bearing surfaces – when the hole and bolt are not perfectly aligned. Working together, the spherical washer and conical seat compensate each other to a maximum of 3 degrees. The washers are available in case hardened carbon steel with a surface hardness of 550HV – 650HV 10. The range of dimensions includes M6 up to M48. The washers are available with different surface treatments including burnishing with light oil film protection, phosphating, and others on request such as mechanical zinc plating, as well as zinc flake coating processes – all carried out in-house. www.growermetal.com

BRALO increases international presence Aiming to strengthen ties with customers and expand the visibility of its brand worldwide, BRALO has increased its attendance at international fairs in 2019, such as Fastener Fair Stuttgart, FASTENER POLAND® and UK Construction Week in Birmingham.

RALO committed itself to a greater international presence, with a positioning strategy that allowed it to better understand the needs of different sectors and meet the demands of customers in a closer way. Events attended this year by BRALO include Fastener Fair Stuttgart, The Commercial Vehicle Show, Lamiera, Fastener Fair USA, SubCon Show, FASTENER POLAND®, UK Construction Week, and finally as every year, BRALO Spain supported its Mexican delegation at Fastener Fair Mexico. To finish the year, BRALO will be exhibiting at MetalMadrid from 27 th – 28 th November on stand 7A41. The Spanish multinational, a leader in the manufacture of rivets, attends an average of ten annual fairs, always highlighting custom manufacturing fixings and special parts for sectors such as construction, automotive, renewable energy and household appliances – not forgetting standard products such as high-quality rivets and nuts, as well as manual, pneumatic and battery riveters. “Thanks to the ten shows positioned worldwide, BRALO increased its international presence and generated a brand image based on quality, innovation, and a competitive delivery service.” www.bralo.com

MS Head,

Provide a Clean and Flush finish

PRODUCTS + TOOLS

Pan head screws with 6-lobe Made of natural nylon, this new range from Bülte is available from M4 to M8, with lengths from 6mm to 60mm depending on the diameter. These screws are used when a wider bearing surface or smoother, more finished appearance is desired, or in material too thin to accommodate a countersunk head.

ue to their head geometry, pan head screws with 6-lobe are designed for light fastening applications. The 6-lobe footprint offers many advantages such as ensuring a good alignment of the tool and enabling the use of automatic, electric tools; as well as optimal force transmission since the driving force is transmitted by the surfaces and not by the edges. There is also no ‘cam out’ effect (tool removal during assembly) known with cruciform prints. “Like all our products, our polyamide fasteners are distinguished from metal screws by their lightweight, stainless and electrically non-conductive nature. The excellent thermal properties and good mechanical resistance of the polyamide make these screws resistant to shocks,” explains Bülte. In addition to nylon, Bülte offers this range in PP, PE, PVDF, and PC on request, materials that are also stainless and therefore resistant to diluted acids, fats, oils, alcohol or petrol. Also available, are glass-fibre reinforced nylon. This polyamide combines mechanical performance with long-term durability and is an ideal solution for highly stressed parts requiring shock absorption. “Our business managers will assist you from design to implementation, and help you make the right choice, with free quotes and samples available on request,” comments Bülte. www.bulte.com

Features Calendar 2020 ISSUE 121: JANUARY 2020

ISSUE 122: MARCH 2020

ISSUE 123: MAY 2020

ISSUE 124: JULY 2020

SPECIAL FEATURES:

SPECIAL FEATURE:

Janus Perspective

wire® Düsseldorf

Made in the UK

Fastener Distribution

Made in Turkey

MANUFACTURING TECHNOLOGY

Steel + alloy wire rod bar

CONSTRUCTION FIXINGS

Chemical anchors + resins

EXHIBITION PREVIEW

EISENWARENMESSE Aerospace

MANAGEMENT + SYSTEMS

Supply chain management Stainless steel fasteners Torque wrenches

ISSUE 125: SEPTEMBER 2020 SPECIAL FEATURE: Made in Italy

MANUFACTURING TECHNOLOGY

Coatings, lubrication + locking technologies

CONSTRUCTION FIXINGS

ETAs

EXHIBITION PREVIEW

Fastener Fair Italy

APPLICATION TECHNOLOGY

Rail

MANAGEMENT + SYSTEMS

Mobile technology

PRODUCTS + TOOLS

Heading + forging

CONSTRUCTION FIXINGS

Light duty fixings

EXHIBITION PREVIEW

Fastener Fair Turkey

APPLICATION TECHNOLOGY

PRODUCTS + TOOLS

MANUFACTURING TECHNOLOGY

Collated fasteners, nailers, staplers + systems

EXHIBITION REPORTS

Taiwan Int. Fastener Show Fastener Fair India - New Delhi Fastener Fair Turkey EISENWARENMESSE

APPLICATION TECHNOLOGY

Electrical + Electronics

MANAGEMENT + SYSTEMS

Manufacturing software

PRODUCTS + TOOLS

Rivets + rivet nuts Battery powered installation tools

MANUFACTURING TECHNOLOGY

Threading, machining + Secondary operations

CONSTRUCTION FIXINGS

Heavy-duty anchors Fastener Fair France

EXHIBITION PREVIEW

Tooling, dies + punches

CONSTRUCTION FIXINGS

Structural steel + cladding fasteners Fastener Fair France

Fastener Fair USA - Charlotte Int. Fastener Show China

EXHIBITION REPORTS

MANUFACTURING TECHNOLOGY

wire® Düsseldorf

EXHIBITION REPORTS

Taiwan Int. Fastener Show Marine

APPLICATION TECHNOLOGY

MANAGEMENT + SYSTEMS

Business intelligence

MANAGEMENT + SYSTEMS

Security screws Drivers, screwdrivers + drive bits

Fastener + Fixing Magazine’s dedicated features take an in-depth look at key topics, products, and applications within important industry sectors.

Fastener Fair USA - Charlotte Int. Fastener Show China

APPLICATION TECHNOLOGY

PRODUCTS + TOOLS

Fastener Fair India - New Delhi

PRODUCTS + TOOLS

Automotive Inventory + warehouse management Nuts, washers + locking systems Sockets + wrenches

ISSUE 126: NOVEMBER 2020 SPECIAL FEATURE: Made in Eastern Europe

In addition to the features, the magazine includes the latest news (tariffs, policies, anti-dumping) product launches, business developments (mergers, acquisitions), and much more. Advertisers can tailor their campaigns to benefit from not just highlighting expertise in a specific feature, but also as part of strategy to build and maintain a presence in the market.

For more information about your marketing opportunities please visit www.fastenerandfixing.com, email sales@fastenerandfixing.com or phone +44 (0)1727 814 400

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Testing, inspection + packing

CONSTRUCTION FIXINGS

Sealants + adhesives

EXHIBITION PREVIEW

BAU 2021

APPLICATION TECHNOLOGY MANAGEMENT + SYSTEMS PRODUCTS + TOOLS

Renewable Energy Storage systems + material handling Nuts, washers + locking systems Tapes + adhesives

PRODUCTS + TOOLS

Welding studs and RIVST80 Rivit’s capacitor discharge welding studs can be used to create joints between bearing pieces and the part to be fastened, such as steel, stainless steel, aluminium, and brass surfaces.

hanks to the company’s range of welding studs, made of resistant and watertight fastenings, the outer surface on which the application has been performed, remains smooth to safeguard aesthetics. Application is very easy as it does not require accessibility from both sides of the sheet as the products can be blind placed. The studs can also be welded onto plates of the same material, and users can choose from threaded studs, internal thread tapped studs, 1 or 2 contact fastons, and insulation nails, which are available in steel, AISI304 stainless steel, aluminium and brass. For the installation of the welding studs, Rivit Srl recommends the use of the RIVST80 capacitor discharge studwelding tool for studs up to M8. Being completely electronic it is not subject to any kind of wear, and it automatically stabilises the variations of the line voltage. The gun, which comes with the tool, works according to the contact welding system and the centering of the studs can be done following an outline, by means of a centering template. The welder weighs 13kg and gun weighs 0.7kg. www.rivit.it

A new CNC machine for Colombo Colombo Giovanni & Figli Srl, a company specialised in the production of high-quality turned parts according to customer drawing, has added a brand new fully CNC multi spindles machine to its production facility.

he new MORI-SAY TMZ842; a full CNC controlled 8 spindles machine with 32 controlled axis equipped with a Pietro Cucchi automatic bar loader, is capable of producing very complex components with very high tolerances and can machine hard materials with a maximum workable diameter of 48mm. Thanks to this new addition, Colombo aims to get into new markets that require high-quality standard and complex components. “This has been a big investment for our company and it will be the first step of a planned process that will take Colombo along a process of technological and organisational growth. With the aim to always be competitive and up to date with increasing market requests,” comments Colombo. Colombo Giovanni & Figli Srl will also be attending Fastener Fair Italy in 2020, and Fastener Fair Stuttgart 2021, and will be pleased to meet visitors interested to learn more about the company and its production capacity and skills.

New marine and fabric fasteners from SD SD Products has expanded its catalogue of marine and fabric fasteners with several new lines, including DOT branded parts, all of which are available from its website.

ll products in the category are manufactured from quality brass and polyacetal, as well as being low cost and easy to use. Spur teeth washers and grommets, plus brass eyelets and rings, are used extensively in the textile industry. Also available, Tri snaps offer an economical snap fastener, ideal for lightweight applications. Common sense turnbuttons are also in the new range and offer positive locking fasteners assembled with a spring mechanism – holding the stud button in position until turned by hand. SD Products stocks a large range of DOT brand fasteners, which are well known for quality and durability. ‘Durable Dot’ and ‘Pull the Dot’ ranges from SD Products are manufactured from heavy gauge brass and 316 grade stainless steel – designed to withstand tremendous amounts of pressure without unlocking.

176 FASTENER + FIXING MAGAZINE // ISSUE 120 NOVEMBER 2019

SD says these heavy-duty components guarantee these fasteners show improved performance and corrosion resistance in the most severe environments. The fasteners are self-piercing, so they can be attached even to the roughest fabrics without the need for pre-punching. Durable Dot can be especially useful in salt water conditions. ‘Pull the Dot’ fasteners are a heavy-duty, three sided locking snap fastener, built to withstand extreme pressure on three sides without unlocking. When pulled on the fourth side, where the ‘Pull the Dot’ mark appears, the fastener releases instantly. “We are committed to providing superior products and services and competitive prices for our customers. Thanks to our large quantities of stock we are able to offer speedy deliveries with next day dispatch to the UK,” comments SD Products. www.sdproducts.co.uk

ADVERTISERS INDEX 310Express......................................................... 170 Abbey Clamps......................................................15 Achilles GmbH..................................................... 11 Acton.................................................................... 159 Advance Spares............................................... 149 Albert Pasvahl......................................................9 Alloy & Stainless Fasteners........................ 178 Ambrovit.......................................................... 1, 13 Apex Stainless Fasteners ............................161 ARK Group (Arpel)........................................... 90 ARK Group (Kamtech)...................................131 ARK Group (Rivco)......................................... 157 Astrotech Steels Private Limited............. 135 Avon Stainless Fasteners Ltd.................... 155 Atotech...................................................................55 Bäcker GmbH & Co KG.....................................53 Bendfast...............................................................161 Berardi Bullionare......................................... 133 Berdan Bolt........................................................ 145 Birlik Baglanti Elemanlari San................. 137 Böllhoff.................................................................. 49 Bomet................................................................... 180 Bossong............................................................... 104 Bralo....................................................................... 92 Bülte.........................................................................67 Brighton Best International..........................31 Carlo Salvi.......................................................... 129 Cetin Civata........................................................ 39 Chavesbao.............................................................21 Ching Chan Optical Technology Co........ 125 Colombo Special Fasteners Srl....................41 Dimac....................................................................119 Don Quichotte....................................................114 DS Fasteners......................................................161

Eisenwarenmesse 2020...........................................93 Eurotec...................................................................75 Evirt Italia.......................................................... 122 Fareast Metal International Co Ltd.........177 Fastbolt....................................................................2 Fastener Fair France.......................................91 Fastener Taiwan............................................... 89 Fastener Fair Turkey........................................87 Fastener + Fixing Magazine.......................175 FastFixSearch.com.........................................113 FastFixTechnology.com................................147 Felo Werkzeugfabrik Holland-Letz GmbH.....54 Fiminox............................................................... 143 Fixi Srl.................................................................... 25 Fong Prean Industrial Co Ltd.................... 173 G & B Fissaggi Srl.............................................. 99 Gala Precision Engineering Private Ltd........25 Gesipa.................................................................... 69 GWI Werkzeug und Stahl Vertriebs GmbH.....77 Hafren Fasteners Ltd.................................... 154 Hang zhou RET trade co ltd...............165, 174 Harrison Silverdale....................................... 143 Heico Befestigungstechnik...........................77 Heller Tools...........................................................19 Hexstone Group..................................................17 Honsel.....................................................................53 Index Tecnicas Expansivas Srl.......................3 Industrial recence.......................................... 165 Jeveka.................................................................. 155 Johan Smit......................................................... 163 Joker Industrial Co. Ltd............................... 163 Jubliee clips....................................................... 155 KINFAST HARDWARE CO LTD................... 139 Lederer GmbH............................................. 22, 24

Bolts • Nuts • Studs Sockets • Washers Specials Made

Lichthart Betriebsgesellschaft mbH........53 LÜLING GmbH & Co. KG .................................76 Lusavouga SA................................................... 4, 5 Marposs...............................................................118 Mayes & Warwick........................................... 163 Merlin Business Software Ltd................... 134 Nakashimada Engineering Works Ltd......35 ND Industries........................................26, 27, 29 National Machinery........................................ 83 Ningbo Londex.................................................. .37 Nord Lock............................................................. 23 Norm Civata........................................................ 33 omniTechnik Mikroverkapselungs GmbH........47 Orderwise............................................................131 Panacol-Elosol GmbH................................... 164 Peter Schroder................................................. 133 pgb - Europe NV............................................... 101 Pinstructure........................................................15 Precision Technology Supplies..................151 PRK Technologies........................................... 135 Puehl....................................................................... 59 Rawlplug .............................................................. 97 Ray Fu Enterprise Co.................................... 135 Reinhardt..............................................................67 Rexlen Corp....................................................... 153 Reyher.................................................................. 137 RFKS........................................................................71 Rivit...................................................................... 179 Robert Grass GmbH..........................................51 Rotorclip................................................................85 Rosmil.....................................................................81 Sacma...................................................................117 San Shing Fastech.......................................... 127 Saspi Tallers.......................................................115

Schäfer+Peters...................................................81 Schnorr................................................................. 93 Schraubenwerk Magdeburg........................ 45 Schwer + Kopka..................................................77 SD Products....................................................... 169 Shanghai Fast-Fix Rivet Corporation..... 169 Sheh Kai Precision Co.................................... 111 Sipa....................................................................... 109 Skako.................................................................... 122 Smith Bullough................................................ 178 Specialinsert..................................................... 159 Spirol Ind............................................................ 159 Stafa.......................................................................... 7 STS-Tectorius.......................................................81 Tecfi....................................................................... 103 Tecno Impianti..................................................121 Teknoform.......................................................... 149 Test GmbH............................................................ 63 Teudeloff................................................................61 Trutek ........................................................ 105, 107 The Insert Company...................................... 143 TITIBI.................................................................... 104 Tobsteel............................................................... 139 Top Screw Metal Corp Ltd........................... 157 UBK........................................................................177 Valenta................................................................ 133 Videx..................................................................... 126 Vipa Spa...............................................................171 Wan Iuan Enterprise Co Ltd....................... 123 Wasi.......................................................................141 WPI Services......................................................121 WTI........................................................................ 137 YUYAO ALFIRSTE HARDWARE CO.,LTD...167 Zago Manufacturing Inc................................15

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