Connecting perfectly Cera

CONNECTING PERFECTLY

Already well known for connector systems for insulating glass profiles, Cera is branching out into new markets globally. Julia Snow reports on a company that has been dedicated to offering innovative plastics solutions for 38 years.

Cera specialises in developing, producing and selling precision injection moulded parts and high-end products for international customers with the highest demands on quality. Thanks to optimised production processes, state-of-the-art manufacturing and in-house tool construction, the company is a leading expert in this market segment today. Cera’s high levels of experience, dedication and creativity result in exceptionally versatile and innovative products.

All under one roof

The company has its headquarters and single production site in Ruderatshofen-Immenhofen, located in South Germany around 70 miles south-west of Munich. The location was a new-build in 2010, and with its cutting-edge machines and maximum output capacity it counts among the top three most modern production facilities of its kind in Europe. “It’s fairly easy to be at the top, given that we built it to our own specifications only two years ago. We were able to create everything exactly as we wanted, with optimised machine layout and everything under one roof,” says the deputy managing director, Mrs Rafeld.

All new machines are controlled by a main computer in the production hall, and the extra capacity helps to increase the output of complicated custom-made products for individual requirements. Items of the highest quality can be produced quickly, reliably and in large quantities. Thermoplastics are processed using 12 injection moulding machines from the leading brand ARBURG.

But investments have not come to a halt with the new location, says Mrs Rafeld: “In the last six months we bought two new machines, and our injection moulding machines are subject to investments on an ongoing basis anyway. With over 1000 different parts they require constant replacement and improvement of tools.”

Products

“Our core products are the connectors for insulation glass profiles,” says Mrs Rafeld “but we can produce parts of up to 200g for any industry or application.”

Under the brand name CERA CONNEXX the company offers angles, connectors ranging from 6 to 20, muntin bars and accessories. The product line represents a highly complex connector system for all conventional profile systems as required by the modern building industry. Whether they are inserted in the profile, close off the end of a frame, block the molecular sieve or allow it to pass through, plastic is an easy-toprocess material in addition to its first-class thermal insulation.

“We are also increasingly getting involved in leisure and sport. Our plastic horseshoe is already used most successfully in competitions worldwide, and it has won us the IF Design Products Award which makes us very proud.” CERA ENDURANCE PRO is a unique plastic horseshoe that is very light and withstands the highest impact through its resilience and excellent damping properties.

And there are more opportunities in the growing leisure sector: “We produce gear levers for a Swiss manufacturer of luxury mountain bikes – a perfect match for us.”

Cera is 100 per cent committed to production in Germany, owing to the superior quality and innovation that is guaranteed by the flexibility and speed of its in-house product development team.

Constant innovation

“We always start with the customers’ ideas – and then try to turn these into a reality. We advise on the process technology or costing, but we are not just a reliable and high quality producer; rather we are a development partner for the design requirements of our customers.”

Cera is highly experienced in the characteristics of special plastics and their areas of applications. The expert knowledge of the highly trained staff is combined with a pleasure in taking on new challenges, so that usually only a short time is needed between the initial idea to the successful market launch.

“Due to ever-changing thermal insulation regulations there is a constant need to improve the properties of windows and doors. Everybody is searching for even better, even more insulated products,” explains Mrs Rafeld. “We are part of this culture of continuous improvement and this benefits our other products too.”

Growing markets worldwide

Currently Cera’s export rate stands at 50 per cent, which is spread out across Europe but also includes the horseshoe business in Australia, says Mrs Rafeld. “We’ve got some very enthusiastic customers out there who have really helped to establish us in the market. In the USA we are seeing the introduction of insulated houses, as there is a clear change in attitudes there after decades of indifference about energy use. And in the UK we have insulation regulations that apply to all newly built houses.”

If orders remain as positive as they are now, another expansion may be on the cards, she adds. “Although we planned generously two years ago, we are already working to full capacity. Luckily we still have some land left if we need to increase our footprint. As traditionalists, we make long-term plans for steady growth and we have just announced very positive annual results. We are looking back on many years of experience, but are also really looking forward to our future development over the coming years.” n

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