Powering success Andritz Hydro

POWERING SUCCESS

Andritz Hydro is a global supplier of electromechanical systems and services for hydropower plants and a leader in the market of hydraulic power generation. In recent years Andritz Kft, the Hungarian subsidiary of Andritz AG, has turned its focus to new products and joined the Andritz Hydro group to improve efficiencies. Edina Beale reports.

Based in Tiszakécske, Hungary, Andritz Kft is a significant producer of energy components in central Europe. The company specialises in the production of components for the energy industry and for water power stations and manufactures high quality heavy weight machines for the paper industry. The firm is able to carry out the entire production process from processing the basic material through welding, heat treatment and milling to surface treatment and assembly for product structures up to 150 tonnes. The factory is therefore capable of producing and delivering complete, fully assembled, insulated components ready for connection to other completed units at construction sites.

Focus on Hydro business

Since May 2015 Andritz Kft has been integrated into the Hydro business unit of the parent company, Andritz AG. This strategic change was based on the short- and long-term market data which showed that 80 per cent of the products being produced in Hungary were required for the Hydro sector. However, the company still continues with the machine making for the paper industry and other component production for all the other Andritz sectors. “We will have to strengthen the supply chain within Andritz, which will improve our capacity use in the long term. Currently there are many initiatives which aim to create opportunities for us to produce new products within the Hydro group; for example, gate closing structures for water power stations in Norway,” says Ms Katalin Balla, sales group leader of Andritz Kft.

The paper industry is still a significant target market, with the most important product being the Yankee dryer cylinder. The steel version of this product is pioneering in its field and was developed jointly by the parent company and the professional team of the Hungarian subsidiary. By replacing cast iron with steel, Andritz created a high-precision drying cylinder that ensures excellent drying rates at low specific costs. The product allows for highly efficient drying by using special material alloys and has the ability to increase the length

and diameter of the drying cylinder so that larger sized paper can be produced. Lamellas and evaporators are also important products for this sector. In addition, the company produces hydrogen and aircooling generator housings for the parent company.

Large investments

Today Andritz Kft employs 429 people and uses over 60 subcontractors for large projects. Its annual turnover is expected to reach €26.5 million in 2015.

Since the takeover in 2007, Andritz has invested a total of €24 million in Hungary; nearly €3 million of which was sourced through government funds. As a result, a new manufacturing hall was developed on the company’s 15,000m2 production site whilst extensions were made to existing production facilities. In order to improve the production process further, new technologies were implemented. The most significant of these included the PAMA drilling and milling machine, valued at €3 million, with dimensions of 24 x 6 m and a round table weighing 100 tonnes: this is unique in Hungary and demonstrates the company’s determination to continue meeting its customers’ high expectations. A 6.5m diameter WALDRICH vertical turning lathe, and a 12m diameter SCHIESS vertical turning lathe have also opened up new opportunities for the company in the field of machining.

Production efficiency was supported with a new rolling machine and in 2008 opportunities were created to carry out the coating activ-

ity in the 10–15m-long closed cabins. In 2015 the company invested again in this area and adjusted its capacities to meet the increased volume, as well as developing suitable storage facilities and implementing technologies for washing products before coating.

Increased demand

The demand for lamella production has doubled this year: instead of 100,000m2 Andritz is required to produce above 200,000m2 in 2015, and is expected to deliver more than 300,000m2 of lamella in 2016. In order to cope with the increased demand the company has already been obliged to significantly reorganise its capacities and has purchased a third laser welding machine.

Future targets

Andritz Kft’s main competitors are mostly in eastern Europe, particularly in Slovakia and Poland, but it is also seeing strong competition from China and India too. “We can only compete with these countries if we win the satisfaction of our customers by providing excellent quality products and adhering to the strict deadlines whilst offering competitive prices. This is only achievable if our planning and production process are working well and if we employ a skilled labour force,” explains Ms Balla.

“Currently our prime objective is to meet the expectations of the Hydro segment. To support this agenda a new member, Erich Köstenbauer, has joined to our management team. Mr Köstenbauer used to be the global product manager of the Hydro sector. Our company is a major employer in this region, and we wish to maintain and strengthen the position of our firm.” n