Diversity in metals ZML Industries

already have a major production presence, and in the longer term we are looking to expand production to include South America and in particular Brazil.”

Mr Verstraeten added, “We are very much an innovation and application driven company and currently we are developing several revolutionary new products, one of which involves flexible electronic circuits which will transform many of today’s automotive functions, especially those relating to heating and steering systems as well as in areas such as car pedals and fuel tank connections. These technological advances will result in significant weight reductions and related cost reductions for the world’s automotive manufacturers.

“In yet another area we are developing an air bag to protect pedestrians in the event of an accident which will be located on the outside of the vehicle. All these significant innovations are at an advanced stage of development. Today, our airbag and other

occupant safety systems meet the highest quality standards, and by our calculations they help to save a life every two hours.”

Global expansion

In 2008, ALT opened its new, state-of-the-art production facility in Romania and has since continued to upgrade and extend its production capabilities there. In 2011, ALT attracted a major new shareholder and with this came new capital for further global expansion. The resulting significant new funding was invested in an entirely new, purpose-built production facility in China as well as in new software, new equipment and product R&D. Capital has also been invested in a new enterprise resource planning (ERP) system from QAD, as well as in a range of the latest digital production equipment.

The new facility in China became operational in 2012 and today supplies the fast growing Chinese market with more than 10 million airbag covers and related airbag systems a year. By the end of 2013 this is expected to grow to more than 30 million products. ALT is continuing to look to the future and is investigating opportunities for similar operations in South America and India.

ALT has also invested heavily in its European production facilities in Romania. This includes new ERP systems (QAD Enterprise Applications) which will enable end-to-end electronic data interchange (EDI) with both its customers and suppliers. Underscoring its commitment to maintaining the highest standards, all ATL’s manufacturing facilities have been independently assessed and certified to international quality standards, TS 16949, ISO 14001 and ISO 9001. n

For further information about ATL’s latest innovative products and services visit: www.atltechnologies.com

DIVERSITY IN METALS

ZML Industries SpA is an Italian leader in aluminium die-casting, grey cast iron casting and the production of copper wire for household appliances and the automotive sector. Industry Europe looks at the history of the company and its activities.

The roots of ZML Industries SpA go back to the late 1960s, when the company started manufacturing components for the household appliances industry. ZML, started by the Zanussi group, was acquired by Electrolux in 1984 and then in 2002 a further ownership change took place with ZML being purchased by an American investment fund. Finally, in 2006, ZML was wholly acquired by Mr Valduga, head of the Cividale group, whose core business is steel production for the oil and gas sector, employs 1500 people and has an annual turnover of around €360 million. The Cividale group is presently led by the heirs of Mr Valduga, the Valduga and Bernardino families.

Since 2002 ZML has increased its diversification, especially towards the automotive sector. Nowadays ZML Industries SpA, which has 580 employees and a turnover of €167 million, is subdivided into three divisions: aluminium, cast iron and copper wire. Currently, the activity of the aluminium division is entirely for the production of components for the automotive industry, supplying all major European car manufacturers, with about 70 per cent of this production for the car industry and the remaining 30 per cent for industrial vehicles. The cast iron division is more diversified, with 45 per cent of its products supplying the automotive industry, 40 per cent the household appliances sector and 5 per cent the mechanical

industry. The copper wire division production is channelled towards the automotive industry for 60 per cent of its output and the household appliances one for 40 per cent.

The global crisis hasn’t affected the company as badly as it affected foundries working for other sectors, and the ZML product quality has meant that the company has been retained as a supplier by clients, even during the difficult economic times. In addition to this, in production terms ZML has very quickly recuperated from the recession.

Production facilities

All production takes place at one site, where ZML has a large 300,000m2 plant, divided into three separate factories. A recent investment consisted of the creation of a new €12 million cast iron production line. At present, ZML is the Italian leader in cast iron and the purpose of this project is not an increase in production volumes but an optimisation of production costs and a widening of the range of products offered, especially in terms of new materials, in order to allow ZML to be in the best possible position in comparison to competitors in other countries, such as