14 minute read
Dedusting the world NESTRO Lufttechnik 74 Composites and compassion
NESTRO LUFTTECHNIK I PROFILE
NESTRO Lufttechnik GmbH has specialised in extraction and filter systems for the past 45 years. Till Uhle, Director Marketing and Sales, shared details of the company’s innovative range with Phil Nicholls.
AS one of the first suppliers in the field of filter technology for the wood industry, NESTRO Lufttechnik GmbH was an early developer of clean air systems. NESTRO technology features the fan located downstream of the filter and thus only charged with clean gas. This arrangement increases fan energy efficiency by up to 30%.
The story of NESTRO began in 1977, founded by Paulus Nettelnstroth, with the first production facility opened in 1978 at Kirch-Brombach in Hesse, central Germany. In 1980, NESTRO relocated to Röllbach in Bavaria, where it developed reverse air filter technology with additional flushing air fans, enabling highly efficient, energy-saving cleaning of filter bags. During the 1990s, NESTRO was a pioneer in the Eastern European markets, building a strong sales network in a relatively short period.
In 1993, the company finally inaugurated its production and office building on a 44,000 sqm site at its current headquarters in Schkölen, Thuringia.
NESTRO today has three production sites, located in Germany, Poland, and Hungary with 300 employees in total. Each site focuses on a strategically defined sub-set of NESTRO’s range, typically with an output tailored to the respective national market.
The NESTRO Group posted impressive sales of over €40 million last year, with customers across five continents and in many different industries. Till Uhle, Director Marketing & Sales, outlined the broad appeal of NESTRO products: “Our solutions are needed wherever dust, chips, cuttings, punching waste, smoke or paint mist are produced during material treatment or processing, and wherever material can be separated using air flow, such as in the waste disposal and recycling industry.”
Mr Uhle was keen to maintain customer confidentiality with regards to current projects but remained clear about the reasons behind the steady growth.
“We serve small and large customers alike,” he said. “NESTRO has small sales orders and large project businesses. This broad positioning in many sectors and in many international markets makes us significantly less dependent on market fluctuations than some of the other market players.
“We are currently experiencing a crossindustry boom in orders, despite significantly higher prices, arising from a necessary surcharge due to the situation in the supply market. Even price-adjusted, the first quarter of 2022 showed the highest order intake in the company’s history.”
The USP of NESTRO products is clear to Mr Uhle: “Setting up, standing and maintenance times, energy efficiency or recycling rates/qualities are all increasingly becoming matters for the focus of managerial attention. NESTRO provides personal support for customers to face-up to these new challenges in providing optimum working conditions.
NESTRO LUFTTECHNIK I PROFILE
“Our systems extract material that is hazardous to health or process-impairing in an energy-efficient manner and thus help clients implement perfect quality air with reduced downtimes. NESTRO systems also convey, shred, separate, store or compact the residual material according to the requests of our customers.”
Deduster upgrades
Innovation continues to drive NESTRO’s performance. Back in 2014, NESTRO launched the first deduster with an air volume of over 7,000 cbm/h approved for indoor installation. Now in 2022, development of this technology has led to a range of dedusters equipped with IE5 synchronous reluctance motors and matching frequency converters. IE5 packages can save operators up to 22% of the energy costs compared to those using IE3 motors.
Mr Uhle shared the features of the next generation dedusters: “The development of the mobile NESTRO deduster series type NE J for indoor installation in the established performance classes is based on the company’s decades of experience in woodworking, in device technology and in the construction of high-efficiency fans.
“The use of clean air dedusters for material extraction is perfect for small and medium-sized companies from many different industries, and always worthwhile for cost reasons.”
NE J dedusters offer multiple savings for customers. Short pipeline routes reduce investment costs and ensure overall low line resistances. The mobile plug-and-play nature of the NE J range that only requires power, a compressedair connection and junction of the pipeline further reduces installation costs. The frequency controlled IE5 reluctance motor achieves an operating efficiency above 90% and thereby reduces running costs.
The filter material guarantees a residual dust content of < 0.1 mg/m³ with the return air; cleaner than outdoor air. As the deduster circulates air without heat loss, customers can significantly reduce heating costs. The addition of an intelligent, certified automatic fire extinguishing system without the use of water or dry chemicals cuts the NE J’s maintenance costs.
Cutting edge investments
Development at NESTRO, confirmed Mr Uhle, is an ongoing process.
“NESTRO is constantly investing in buildings and machines at all three locations,” he explained. “Last year, for example, a new cutting / shearing / bending system from Prima Power was put into operation in Germany connected to the automatic high rack stocking area. This has given us clear advantages in terms of productivity, economy, precision, and flexibility.
“An automatic loading unit for the supply of raw sheet metal as well as a system-integrated load/batch robot between the cutting/shearing segment and the bending segment guarantee automatic, multi-shift operations if required. Now for the first-time metal sheets with a length of up to 4 m can now be tooled.”
Additionally, pre-cut parts with a length of up to 3m can be bent in a highly adaptive manner. The bending segment can carry out positive as well as negative bends, even with complicated geometry, without turning the sheet while the tools are automatically adapted to part and material. With much less manual work, it is now possible to produce very demanding parts – using a manufacturing specific design – which leads to significant cost savings in the downstream working process.”
Competition in the field is strong, but Mr Uhle is confident of NESTRO’s position.
“Our employees, our distributors and our specialist retail partners are all excellently established on the market and have a lot of experience and extensive knowhow in air technology. We not only offer a product, but always a systemic solution, possibly with extensive government funding opportunities, to completely satisfy each customer.”
The route to a satisfied client begins with NESTRO’s relationships with suppliers.
“In these difficult times,” Mr Uhle explained, “our long-standing supplier relationships are crucial to being able to survive
on the market. Quality has always been an important factor for us here.
“Now our partners are helping us, especially in the current critical areas of delivery capability and reliability. I think each of your readers knows how challenging these two issues are today, which had otherwise always been taken for granted. These solid partnerships with our suppliers are the key factor for every project in 2022. Conversely, our suppliers can also rely on us as customers.”
Sustainable growth
Moving into 2022, Mr Uhle identified two main trends: energy efficiency and intelligent control technology.
He explained: “In several countries there are subsidy programs for replacing old, more energy-intensive system technology with new ones. For this, energy efficiency criteria must be met. We believe that these requirements will become even more stringent due to climate change.”
In 2020, NESTRO received the REC Sustainability Award. “Our group of companies has positioned itself completely sustainably,” Mr Uhle said. “NESTRO generates its own electricity at two locations using polycrystalline photovoltaic modules with a total output of 530 kWp. We also generate heat at all three locations.
“At NESTRO, we believe that filter and extraction technology is a sustainably growing business, as the requirements for clean air in production facilities are becoming more demanding, and not just because of occupational health and safety laws.”
Yet, challenges remain for NESTRO. Supply bottlenecks – especially of electrotechnical vendor parts – have impacted production and delivery times. The rural locations of NESTRO plants exacerbate the growing challenge of employing skilled workers, as young people are drawn to metropolitan areas.
Despite these challenges, Mr Uhle maintained a positive mindset: “We want to continue to grow internationally and defend our consulting leadership in the market. To this end, NESTRO will continue to expand production in terms of space and technology at all our locations in the upcoming years. We are continuously revising our product portfolio to be able to offer customers simple, comprehensive, and energy-efficient system solutions.”
NESTRO’s team spirit carrying it into the future is evident to Mr Uhle: “It is of course great to accompany NESTRO with its motivated team on a sustainable growth course and to permanently establish it on the market as a high-quality supplier. In addition, it is absolutely satisfying to work for a company whose products ensure a cleaner and therefore more liveable environment.”
He concluded: “The flat hierarchies in our family business facilitate exchange and enable quick decisions. It is said that the fast eat up the slow: we’ll keep our appetites.” n
DEBOTECH I PROFILE
Composites and
A pioneering company manufacturing carbon fibre and composite parts, deBotech has over 20 years’ experience in delivering advanced solutions to industry leaders, sportspeople, and specialist applications. Utilising advanced manufacturing techniques and a state-of-the-art production facility, deBotech is poised to continue its meteoric rises in this sector. Jordan Yallop caught up with CEO Hans deBot, or ‘Carbon Hans’ as he’s known by his peers.
IN the late 1990s, Hans deBot would spend many nights in his small garage, toiling away until the early hours manufacturing and finessing carbon fiber components and refining his ambitions.
Today from his office in Mooresville, North Carolina, Mr deBot, CEO of deBotech remains exceptionally humble about a career that has quite literally flashed before his eyes. Those ambitions, he admits, have paid him back big time.
At the core of these life-changing moments, with his beloved wife, Jamye, together with his daughter and son by his side, is carbon fibre, whether as components for NASCAR teams or providing for such industries as aerospace, aviation, maritime, and the military.
The demand for deBotech’s expertise is simple: the desire for a lighter material compared to traditional heavier ones for all kinds of applications. Carbon fibre is king whether it be for land, sea, or air.
More than 20 years back, Hans deBot worked for a sailboat mast manufacturer in Charlotte, North Carolina. During this time, the company, which mainly used aluminium to build sailboat spars, began a carbon fibre division.
“The company brought someone in, and he failed. So, I was asked to have a shot at it and I helped develop a process to build a one-piece continuous fibre hollow sailboat spar for Americas Cup boats and race boats all over the world,” recalled Mr deBot.
Land, sea, and air
Having anchored his expertise, and running the company’s engineering division, Mr deBot generated interest from NASCAR racing teams in his local area of Mooresville – Race City USA – to build carbon fibre parts for their vehicles.
It was in the offcuts or scraps generated from the carbon fibre during his daytime job, that he spotted an opportunity to reuse for other applications and race car parts. So in 1998, deBotech was formed.
“My old employers thought it was a good idea, but two weeks later, the owners split, and that interest died. So, I decided to do it on my own. I worked in the day job till 9pm and worked diligently in the garage of my house till the early hours, developing carbon fibre parts for racing cars,” he affirmed.
Mr deBot said his side business kept growing, still predominantly within automotive until he was challenged to build a bobsled for one of the US teams for the Salt Lake City Olympics in 2002.
“I’d never built a bobsled in my life, but it was a new challenge. I built a bobsled and made it to Salt Lake City. The Technical Director from USA bobsled, Bob Cuneo, called and said: ‘Hans, that’s a work of art, let’s get working with you.’”
Since that day, Mr deBot has worked with the US bobsled team, even seeing the team claim the gold medal in 2010. He has been building the full bobsleds and skeletons since 2012.
DEBOTECH I PROFILE
On the automotive side, deBotech has been heavily involved with General Motors since 2014 and produces carbon fibre components for its vehicles. On the 2019 ZR1, deBotech built the majority of the carbon fibre products and is now working on the new mid-engine C8 Corvette, and other multi-level products for future Corvette models.
“Our state-of-the-art production facility and advanced manufacturing techniques ensure each part we produce is held to aerospace tolerances,” asserted Mr deBot. “We utilise a total systems approach, encompassing design support through production to ensure customers are satisfied.”
He added: “We are currently in expansion mode and want to ramp back up to not only two full production shifts, but a third. It is an open invitation to anyone in the UK and Europe who wants a great career to look us up and consider coming out here.”
Such is the demand for deBotech’s products that 75% of output is dedicated to automotive.
Untapped potential
Mr deBot pinpointed one challenge in general that is potentially stopping the sector from showing its true potential: skilled manpower.
“Finding self-motivated, self-driven and focused individuals is becoming more difficult,” he said. “We have 12 million unemployed in the USA, but deBotech has difficulty finding 75 people who want a rewarding career and to help us expand further.”
He added: “The automotive OEM world is very challenging, but we have the rigours, resilience, and tenacity to succeed. What sets us apart is the level of technology and to build better, provide the best customer service, and enjoy the journey. That’s why we have close relationships and support suppliers and clients alike. Ultimately, we are committed to being the number-one carbon fibre and advanced composite parts manufacturer in the world.
“This industry has one of the greatest potential growths wrapped around smart vehicles, energy, conservation, safety: all these avenues carbon fibre has input into.”
Mr deBot explained that automation is being used for certain aspects of the manufacturing process currently.
“We’ve introduced quite a bit of automation in one of the stages, which is preparation for coatings and paint; we have a lot of automation associated with any bonded components. When you are bonding any structures together, it’s all done with automation robots.
“That’s the one thing about unique building, they’re still artistic and style prod-
ucts, and it still takes an artisan to do it, which is what I love about it, as a person can feel very self-rewarding to know that it’s an artist building the product rather than just some guy standing in a spot pushing a button every day.”
A composite business
Mr deBot revealed the company was currently engaged in research work for an American doctor working in the UAE to develop a donor heart transport unit. But the medical applications for the company’s products is not limited to humans.
“We’re also working with a vet, Bill Bickley, of PALS, from Texas, who approached us wanting to make carbon fibre prosthetic limbs for dogs. I looked at the product, believed in it, and we undertook the R&D ourselves and got to a level where it now works. There’s nothing like seeing the joy in an owner’s face or the happiness in the dog giving them their mobility back. It is truly inspirational.”
He added: “Carbon is growing in levels of excitement and energy conservation all over the world. People want to build lighter cars, but in motor racing, vehicle weight has always been critical.”
Growth and volume have continued a substantial upward trajectory for the company, while expertise and technology have combined to build parts better, lighter and more complex. It is the experience of the company that sets itself apart from the competition and Mr deBot is of the firm opinion that this is not an industry anyone can walk into.
“We can provide more technologically advanced products that others simply can’t manufacture,” stated Mr deBot. “I understand carbon fibre, plus I am not afraid to have the backbone to take risks. I have challenged myself many times, told clients to give me a shot at what they want, and I can build their products.”
Mr deBot was keen to stress that if you’re willing to work with passion, then he will welcome anyone from anywhere because deBotech is ready to continue its growth.
“Even though we see challenges every day, you’ve just got to figure out how to work the challenges and make the positives shine well above the negatives that we’re all dealing with currently,” he concluded. n
