Strong link BorgWarner

sTrong link

American automotive components manufacturer BorgWarner has created 600 jobs by investing 15 billion forints (44.4 million euros) into their three production plants in Oroszlány in Hungary in the last three years. BorgWarner Oroszlány Kft today is a strong link with great future prospects within BorgWarner’s global operation. Edina Beale reports.

One of the most important challenges in all industries today is to create solutions that will enhance a cleaner and more energy efficient world. Companies in the automotive industry have a major task to deliver energy saving transport solutions and BorgWarner has been focusing on this area for decades. They have developed technology systems that improve the efficiency of the vehicle, reduce emissions and increase performance. The R2S two-stage turbocharger system is a prime example of their pioneering solutions. It uses an electric actuator instead of the traditional vacuum technology to move the valves, so the vehicle responds quicker whilst significantly reducing emissions.

Dynamic growth

BorgWarner has been manufacturing innovative technologies in Hungary for many years. Located 76 km (47 miles) outside of Budapest, the Oroszlány facility produces state-of-the-art turbochargers for gasoline and diesel engines. The factory was established in 2001 in order to assemble turbochargers to serve the Audi factory in Hungary but soon began to manufacture the products themselves. The company has seen dynamic development ever since and today the Oroszlány site is the second largest turbocharger production site in Europe.

In 2017, the 14,000 metres squared production area of the turbocharger producing factory has been extended by another 7,000 metres squared. This unit, now operating at full capacity, required an additional 350 staff. The company’s current product portfolio includes BV turbochargers with variable turbine geometry, turbochargers with waste gates for diesel and gasoline, and turbochargers with twin scroll. The products from this business unit are used by manufacturers of personal cars, light/medium/heavy trucks and commercial vehicles and serve many globally renowned European automotive companies including Audi, Volkswagen, Fiat, GM, Volvo, the PSA group and BMW.

The Hungarian factory does not only impress with its size but also with its modern energy efficient operations. The facility uses waste heat from air compressors and furnaces and will recycle rainwater for watering lawns as well as condensation wastewater. Additionally, the building uses linear fluorescent lamps (LFLs) in most of the production and office areas, and compact fluorescent lamps (CFLs) in the remaining parts of the facility to reduce energy consumption.

extending product profile

In addition to turbocharger production, now there are two more business units in operation on the Oroszlány complex, which covers an area of 35,000 metres squared and employs more than 1,400 people. In 2015, BorgWarner opened its TTS production facility to provide capacities that allow the company to meet growing customer demand with localised production. They began to manufacture hydraulic pumps for ‘pre-emptive’ AWD systems, complete transfer case units for Jaguar Land Rover and related spare parts for OEMS. BorgWarner’s AWD solutions contribute to enhanced vehicle traction, improved driving dynamics and better fuel economy. Later in the same year, another business unit, BorgWarner Emission Systems was established to manufacture advanced products including exhaust gas recirculation (EGR) tubes, valves and coolers as well as thermostats – all key technologies for modern engines aimed at reducing emissions.

Good prospects

Attila Bogár, the managing director of BorgWarner Turbo Systems Kft, has been working for the firm over eight years. He has always been interested in innovative car technologies as his career has always been connected with the automotive industry. Mr Bogár believes the two main components essential to achieve success are quality and reliability. He sees incredible opportunities in innovations in the automotive sector: “The field of innovations in this industry is extraordinary as changes are obvious and very fast; therefore there is no need to look back decades but enough to examine the new developments at the end of the year.”

The managing director also highlighted the ideal geographical position and large capacities of the Oroszlány campus which attracts car manufacturers like Audi, Mercedes and Opel operating in Hungary as well as Tier 1 and Tier 2 automotive suppliers.

According to Mr Bogár the future prospects of the automotive industry will be largely influenced by the stability of the Eurozone in the next few years. Contrary to Europe, Asia and parts of China can expect more stable and dynamic growth in this sector. Quality requirements and regulations are additional factors that will influence the pace of production. The increase in energy prices are forcing manufacturers to produce vehicles that are more efficient but at the same time smaller in size – 1.6 litre engines instead of 2 litre ones are already available on the market. The opportunities will change according to market needs.

Safe operation winner

With its dynamic development and high-quality standards of operations, BorgWarner Oroszlány Kft has set an example for other international BorgWarner sites. Whilst constant expansion the company has managed to maintain their focus on safe operations and has won the Work Safety prize on several occasions. This is a prestigious award for completing one million working hours without accidents that require reporting. The Hungarian firm is the only company among BorgWarner’s 74 global factories that has won this award five times in a row. With this recognition the company received a USD 20,000 prize, which was donated equally between the local fire and ambulance services and a kindergarten. n