Manufacturing-Journal vol. 5/4-2009

Manufacturing Journal Volume 5/4 - 2009

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magazine

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The World of Business

Leader in digital technology

Austrian technology Opening up new applied in Russia opportunities

page 41

page 46

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Manufacturing Journal

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www.manufacturing-journal.net

Covers All sides of International business

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PR EL UD E

Dear Readers!

I

would like to recommend reading the latest edition of Manufacturing Journal. In current issue you will find articles related to the following industries: electronic, brewing, rail, food, HVAC, plastic and packaging. I strongly encourage you to read the article about LG Electronics Mława Sp. z o.o. which celebrates 10th anniversary this year. The company is the global leader and technology innovator in consumer electronics, mobile communications and home appliances.

LG Electronics Mława contributes to the global presence of the LG brand, maximizing profitable growth of the corporation. The LG success is discussed by CEO Mr Jang Hyeu and Corporate Director Mr Daniel Kortlan.

Also, I suggest reading the article about the Russian Group Proplex, one of the leading companies in production and distribution of PVC sections.

The company’s president, Mr Alexandr Golikov, shares his experience with us and tells how to run a successful business in Russia.

Apart from the above, you can read about the Polish company FAKRO Sp. z o.o., which is the second biggest world producer of roof windows.

Success of the enterprise was recounted by President of the Board, Mr Ryszard Florek. In the subsequent sections of the magazine you will find an article about RZD, undeniable leader in rail transportation in Russia.

I hope that everyone will find a subject of their interest in the interviews with industrial leaders which I put forward to you in the current issue of the magazine. We also believe that we can help you build your further success.

We wish our present and future readers numerous business contacts.

Editor:

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CONTENTS

Contents:

Managing Director Patryk T. Zborowski

1 2 4 12

Editor Patryk T. Zborowski Profile Writers Karolina Burkiewicz Kateryna Ferdyn Agata Nowak Szymon Skrypoczko Bartosz Sowiński Aleksandra Strojek Bożena Wałach Berenika Wilczyńska Marcin Zimny

Prelude Contents News Country profile

Art Director Wojciech Kosmowski Project Managers Agnieszka Bechta-Ziobro Katarzyna Marciniec Kamila Piekulska Administration Wioletta Adamczyk

14 The partner to rely on 17 Traditional Russian drinks and country’s pride 20 Quality from experience 24 Ukrainian beer no. 1 29 The taste of tradition captured in a bottle 32 Innovative solutions 35 Nearing excellence in steel and aluminium constructions 38 It’s hard to stay on the roof without falling – reliability of Termatex products 41 Leader in digital technology 46 Austrian technology applied in Russia 52 Russian Railways links East,West, North and South Eurasia

Z-MEDIA Długa Street 48/38 31-146 Cracow Poland e-mail: info@manufacturing-journal.net advertising: pz@manufacturing-journal.net phone number 1: 0048 12 4337115 phone number 2: 0048 12 4337065 phone number 3: 0048 12 4337066 fax number: 0048 12 4337116 web: www.manufacturing-journal.net

© Manufacturing Journal 2009 No part of this publication may be reproduced in any form for any purpose, other than short sections for the purpose of review, without prior consent of the publisher.

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Contents 2009-10-06 21:45:22

EN TS CO NT Keeping your food in a safe place 55 Dynamics in all aspects European standards and innovative technologies Outstanding cosmetics and household chemical products Innovative approach to public transport

58 61

Eco-friendly and innovative refrigeration manufacturer Opening up new opportunities Customer needs – reason for expansion Quality in the first place Excellence steeped in history and tradition

69

Index:

63

Articles:

66

Aflofarm Sp. z o.o.

Amber Brewery Belkommunmash BOLARUS S.A. Edbol Esteban Espuna Fakro Sp. z o.o.

Intersilesia Mc Bride Polska Sp. z o.o.

Keller Polska Sp. z o.o.

KREIS PACK Sp. z o.o.

LG Electronics Mława Ltd. Obolon CJSC Ochakovo CJSC „PAFAL” S.A. Proplex Group Russian Railways “SEST-LUVE-Polska” Sp. z o.o.

Stalfa Sp. z o.o.

TEDEX PRODUCTION Ltd. TERMATEX Sp. z o.o.

Zeller Plastik Poland Sp. z o.o.

72 75

Advertising:

79 82

A.M.P. snc CHRIVA GmbH Cryovac EKA – Production Sp. z o.o.

Grace GRUBER & CO Group GmbH „Gryf” S.A. Herbold Meckesheim GmbH Kale KME Germany AG & Co. KG „PICARO” Piemme s.a.s.

RAWIBOX S.A. Reimelt-Henschel GmbH „STYROMAX” P.P.H.U. „TRANS-LEM” Vem Wytwórnia Opakowań Drewnianych

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58 29 66 69 14 20 72 63 32 55 41 24 17 82 46 52 75 35 79 38 61

78 26 23 44 74 51 16 50 46 78 44 50 44 50 44 62 68 44

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On the sunny side

BASF specialty foam in solar collectors from the heating technology company Viessmann. The international heating systems manufacturer Viessmann, Germany, now uses Basotect® to insulate its solar collectors. The light, flame-retardant melamine resin foam produced by BASF is fitted to the side walls and the rear of flat-plate collectors. Flat-plate collectors capture solar radiation and convert it into heat. Basotect shows good insulation properties over a long period, even when exposed to high temperatures. It positively influences the air exchange in the collector at different climatic conditions. And in contrast to conventional insulation materials, the BASF melamine resin foam can be cut into different forms. A Viessmann solar combi-system with Basotect flat-plate collector insulation was pronounced test winner by the German consumer organization “Stiftung Warentest” in

March 2009, with a rating of “good”. For collectors to absorb as much sunlight as possible throughout their entire service life, durable and heat-retardant materials are necessary. Basotect releases practically no volatile substances that could obstruct solar radiation, e.g. as fogging behind the glass panels of the collectors, and hence reduce the efficiency of the solar system. Because of its good thermal conductivity of <0.035 W/m*K and the intelligent shaping of the insulating pieces, Basotect is able to achieve the same insulating performance as mineral wool, but with less material usage. Basotect makes collector installation easier: It is flexible, fiber-free, and can easily be cut to the contours required. “With the BASF specialty foam, we have found a material that improves the quality of our flat-plate collectors and, at the same time, makes it easier for us to manufacture them,” says Sig-

urd von Wenzler, project leader for solar technology at Viessmann. “Compared to the previous standards, we have further increased the efficiency of our new generation of collectors, thanks to Basotect.

This means that we are able to offer our customers systems that are of greater interest from an economic point of view.”

Flat-plate collectors consist principally of a safety glass panel, an absorber (usually a selectively coated metal sheet) and metal piping, through which an antifreeze fluid flows. When sunlight shines through the glass panel onto the absorber, the absorber transforms the radiation into heat and delivers it to the fluid in the pipes. From there, the heat is transported into the hot water circuit of the house. If the solar collector system is complemented by a heating supplement, house owners can save up to 30 percent of the annual cost of conventional fuel for the heating of the house.

Thanks to its favorable combination of different properties – it is temperatureresistant and flame-retardant, lightweight, flexible, sound-absorbing and thermally insulating – Basotect is used to acoustically and thermally insulate buildings, cars and trains. The thermoset foam is available in several grades for various applications. For example, it protects the sensitive satellites that the Ariane 5 launcher delivers into space. It is used in Beijing's Olympic swimming stadium as acoustic damping in a new type of suspended structure, and it will soon be found in the planes by the American aircraft manufacturer Boeing.

Rectification to the article from page 34-36 published about ZPAS group in the previous issue 4/4-2009, written by Agata Nowak.

In this article Error has appeared In relation to company ‘’ZPAS’’ Group homepage website address– instead of correct company website: www.zpasgroup.eu We have placed erroneous information: www.wolimex.com.pl We wish to underline one more time, that correct internet website address of ZPAS Group is: www.zpasgroup.eu This error has appeared from unintentional guilt trough oversight of proof-reader. We wish to apologize ‘’ZPAS’’ Group for this oversight.

From Editorial staff of Manufacturing Journal

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News 2009-10-06 21:45:23

NEWS

LEDs light the way for planes

OSRAM and Safegate jointly develop robust and efficient LED lighting for taxiways. The ever-increasing volume of passengers and freight in global air traffic makes greater demands on safety too. Because of its major impact on passenger safety, airport operators are paying special attention to the lighting of runways for take-off, landing and taxiing. Lighting manufacturer OSRAM and Safegate, specialist for docking guidance and lighting systems at airports, have now developed resistant and energy-efficient LEDs for taxiways. Conditions at airports are a tough challenge for light fixtures and lamps. Systems have to be capable of withstanding greatly fluctuating temperatures and vibrations and adhere to precisely defined colour spectra and light distribution levels at the same time. OSRAM and

Safegate have now developed an LED module of the Zelion product family for airport applications with 2-8 LEDs in yellow, green and red, which meet all these requirements. They can be used in numerous areas, including various tarmac operations such as the taxiway centre line, stop bar and clearance bar. Dirk Wittenberg, Senior Product Manager (SP SSL) at OSRAM explains, “The challenge was to attach the lens securely to the circuit board despite the extreme environmental and safety conditions on the runway. Together with Safegate we have found a way to develop a robust and efficient LED solution, which meets the extremely high standards of international air transport”. The LED circuit board also enables significant energy savings: two LEDs of 3W each (green) or only 2.5W (red and yellow) replace a 40W halogen lamp. Maintenance costs can also be greatly reduced, as the life of an LED is at least three times that of a halogen lamp. The LED modules are easily dimmable and by producing coloured light via LEDs directly this makes the previous use of colour filters unnecessary. The colour spectrum of the LEDs used meets all the global standards in force. They can therefore be used internationally without restrictions.

Anheuser-Busch InBev Completes Sale of Four Metal Beverage Container Manufacturing Plants Anheuser-Busch InBev (Euronext: ABI) (NYSE: BUD) announced today that it has completed the previously announced sale of four metal can and lid manufacturing plants from AB InBev’s U.S. metal packaging subsidiary, Metal Container Corporation, to Ball Corporation (NYSE: BLL) for an aggregate purchase price of 577 million USD. As part of the transaction, Ball Corporation has entered into a long-term supply agreement to continue to supply Anheuser-Busch InBev with metal beverage cans and lids from the divested plants. Ball has committed, as part of the acquisition agreement, to offer employment to each active employee of the plants. The sale of this group of soft drinks-focused plants is part of AB InBev’s ongoing de-leveraging program and generates proceeds that will be used to pay down debt incurred as a result of the combination of InBev and Anheuser-Busch. Deutsche Bank AG and Lazard Frères & Co. LLC acted as financial advisors and Sullivan & Cromwell LLP acted as legal counsel to Anheuser-Busch InBev.

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Siemens opens new green production facility in Colombia €70 million investment to create 500 jobs in Bogotá region. Siemens AG is opening a new large-scale factory in Tenjo, a suburb of the capital of Colombia, Bogotá – and thereby laying the basis for its even stronger growth in the region. The company is investing €70 million in the new green production facility, which will meet the highest standards for energy efficiency and ecofriendly production. The new factory will create 500 jobs for the Tenjo / Bogotá region. Products from all three Siemens Sectors – Energy, Industry and Healthcare – will be produced at the facility under one roof. The President of Colombia Álvaro Uribe Vélez and Siemens President and CEO Peter Löscher took part in today’s opening ceremony.

“I’m very pleased that we’ve been successful at Tenjo in harmonizing sustainable resource-saving production with the most advanced production standards.

Our largest investment so far in Colombia is the basis for a long-term commitment in this country,” said Peter Löscher.

The production facilities occupy an area of more than 96,000 square meters,the equivalent of ten soccer fields. In addition to transformers, electric motors, ventilation systems and hearing aids will be manufactured. The combination of several production lines will require a high degree of technical specialization.

The specially created free trade zone in Tenjo will enable Siemens to export the products manufactured there to some 20 different markets in the Americas as well as to China. About two thirds of the products manufactured at the facility will go for export. Siemens already has 5,000 employees in the Austral-Andina Region, which in addition to Colombia includes Argentina and Chile.

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Unilever to acquire the personal care business of Sara Lee Leading brands such as Sanex, Radox and Duschdas strengthen category leadership in Skin Cleansing and Deodorants. Unilever announced that it has made a binding offer to acquire the Personal Care business of the Sara Lee Corporation for €1.275 billion in cash. The transaction is subject to regulatory approval and consultation with European employee works councils. Paul Polman, CEO of Unilever said: “Personal Care is a strategic category and a key growth driver for Unilever. This transaction builds on our portfolio in Western Europe and also in Asia. The Sara Lee brands enjoy strong consumer recognition, offer significant growth potential and are an excellent fit with Unilever’s existing business.” Vindi Banga, President Foods, Home & Personal Care added: “We are delighted to have the opportunity to acquire such a strong stable of brands, which will help build on our global leadership positions in Skin Cleansing and Deodorants. They are a perfect complement to Unilever’s existing portfolio of brands like Dove, Axe and Rexona.” The acquisition will strengthen Unilever’s leadership positions overall in Western Europe. In addition, there is significant potential to build these brands in developing and emerging markets, which already generate approximately 15% of their annual sales. The Sara Lee brands generated annual sales in excess of €750 million with an EBITDA of €128 million for the year ending June 2009.

Heineken N.V. issues EUR400 million 7-year Notes Amsterdam, 1 October 2009 - Heineken N.V. announced today that it has successfully placed 7-year Euro Notes for a principal amount of EUR400 million with a coupon of 4.625%. Through this transaction, Heineken has taken advantage of strong credit market conditions and has improved further its debt maturity profile at attractive rates.

These Notes have been issued under the company’s European Medium Term Note Programme and will be listed on the Luxembourg Stock Exchange. The proceeds of the offering will be used to partially refinance existing debt and for general corporate purposes. The Notes were placed by Bank of America Merrill Lynch, Barclays Capital, Fortis Bank Nederland and ING Bank.

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News 2009-10-06 21:45:25

NEWS

Samsung Electronics Ranks 10th Globally Among Corporations Responding to Climate Change Samsung Electronics Co. Ltd., a global leader in electronics, today announced it was selected out of 500 FTSE companies to join the Carbon Disclosure Leadership Index (CDLI), ranking first in Asia and 10th out of 50 top global companies. Each year, the Carbon Disclosure Project (CDP) assesses corporate policies and activities companies engage in to respond to climate change. The CDP held its Global CDP Forum on September 21 where they announced their findings for 2008. Samsung Electronics was the only Asian-based company included in the CDLI and one of only four IT companies selected overall.

Based in the UK, the CDP represents 475 institutional investors from around the world with combined assets under management in excess of $55 trillion. The CDP was established as a not-for-profit organization and project to research global corporations’ influence on climate change and the quality of their response to it. Since 2003, the organization has analyzed opportunities and crises associated with climate change, carbon emissions and reduction targets and current emission management among corporations. These results are tallied every September, followed by a presentation of the CDP’s Annual Global 500 Report. The findings from the CDP also provide an evaluation tool for institutional investors to determine qualitatively how corporations are responding to global warming.

Only the top 10 percent of the 500 corporations selected using the UK FTSE standard are included in the CDLI, showing they have a significantly higher benchmark and a stronger commitment to preventing climate change. This year, Samsung Electronics devised a climate change response strategy by performing a detailed analysis of elements involving crises and opportunities regarding climate change. Several aspects of its program were received positively, including external verification of its carbon emissions, an analysis of financial implications of risks and opportunities from climate change, and the formulation of a holistic carbon emissions manage-

ment system. While presenting its green business vision and strategies in July, Samsung Electronics announced by 2013 it would reduce greenhouse gas emissions intensity normalized by sales from manufacturing facilities by 50 percent compared with their 2008 levels. Starting this year, Samsung will also improve its energy efficiency by 40 percent for the next five years, reducing greenhouse gas emissions from product use phase by 84 million tons. “We are pleased that Samsung’s accomplishments with green business initiatives were acknowledged by the CDP report,” said Yoon-Woo Lee, Vice Chairman and CEO of Samsung Electronics. “Samsung is committed to sustainable business operations and will further embrace our corporate social responsibility to actively participate in solving the issues that face our environment.” “Companies recognized in the Carbon Disclosure Leadership Index are rewarded for high quality responses to CDP, which demonstrate a good understanding of how climate change is impacting their business and how it will affect them in the future,” said Paul Dickinson, chief executive of the Carbon Disclosure Project.

“Companies which control their risk today, while managing their emissions and seizing opportunities to produce low carbon goods and services, will find themselves in the best position to prosper in the low carbon economy of the future.”

Philips and Epistar conclude patent license agreement Today Philips (NYSE:PHG, AEX: PHI) and Epistar announced that they have reached an agreement to amicably settle the current intellectual property disputes between the companies. Philips has granted Epistar a license under its AlInGaP LED technologies. With the license agreement, all claims and counterclaims are dismissed. The exact terms of the license will not be disclosed.

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Alstom will provide train control and signalling system for the new Bangalore metro network in India Alstom and its partners* have signed on 16 September a contract with Bangalore Metro Rail Corporation Ltd. to equip the first two lines of the new metro system with advanced train control solution. The contract is valued a total of € 91 million, of which Alstom’s consolidated share is around € 57 million. Alstom will provide the design, manufacture, supply, installing, testing and commissioning of the train control and signalling system for line 1 and 2 of this new metro system. It includes the Urbalis 200 Automatic Train Control system which will ensure optimal safety, flexible operations and heightened passenger comfort. This fully proven solution has been successfully deployed in many cities in the world. In India, Alstom has supplied the same solution to New Delhi metro line 1 and 2, and is currently delivering the extensions of these lines. Bangalore line 1 and 2 lines will enter into revenue services in September 2012. The Bangalore Metro has been designed for a capacity of 40,000 passenger per hour and per direction. The number of passengers expected to travel on the metro network everyday is estimated at 1 million, and could reach 1,6 million in 2021. This project will involve several Alstom units in Bangalore and Coimbatore in India, Saint-Ouen and Villeurbanne in France, and Bologna in Italy. “This contract confirms Alstom’s commitment in India as the country embarks on its rail expansion initiatives” said Jojo Alexander, Managing Director for India. * The consortium is led by Alstom Project India Limited (APIL) and composed of Alstom Transport SA, Thales Security Solutions & Services Portugal and Sumitomo Corporation.

DB Schenker and TransContainer to operate Joint Container-Hub in Riga

DB Schenker and TransContainer, the freight subsidiary of the Russian railways, RZD, are planning a joint container hub at the DB Schenker Logistics Park in the Latvian capital, Riga. The new transshipment center aims to make container traffic between the economic regions in the Baltic States and Scandinavia such

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as Russia, central Europe and the central Asian states more effective. Both partners hope to offer their customers multimodal international transportation services via Riga and thus gradually shift more containers to rail in a targeted fashion. Mr. Karl Nutzinger, Member of the Management Board of Schenker AG,

said: „It is the first cooperation between DB Schenker Logistics and TransContainer in Eastern Europe. It will allow us to offer our customers more attractive combined services.” Containers will be transferred between rail and road. International freight will be consolidated at the Riga Terminal of the DB Schenker Company, SIA Schenker. Cooperation with TransContainer includes the use of their containers beyond the borders of Latvia. Freight will be loaded onto Russia’s broad gauge. Customs formalities will also be dealt with directly on site.

In direct comparison with the transportation by truck, this reduces the wait at borders and minimizes transit times.

Freight trains are able to clear the border between Latvia and Russia within hours, while trucks can take several days of waiting in traffic jams to enter Russia.

Pre-declaring goods and preparing the necessary documents in advance are also designed to achieve short transit times on rail. This will also allow to reach destinations in Central Asia and western Russia faster.

News 2009-10-06 21:45:27

NEWS

Voith Turbo: SensoTop Fuel Consumption Advantages Proven in Continuous Field Tests In preparation of the market launch of the new topographydependent gear-shifting program SensoTop, extensive continuous field tests were carried out and evaluated. The choice of test applications covered a wide spectrum of topographical and traffic conditions. The savings potentials of SensoTop were demonstratively proven both in cities with flat topographies and in demanding application profiles. Taking up approximately 30 to 40 percent, fuel consumption constitutes a significant share of the operating cost of citybuses. Rising oil and consequently higher diesel prices sharpen the focus of transport operators on consumption-optimized vehicle technology more than ever. Moreover, an increase in fuel efficiency also means active protection of the environment: lower diesel consumption goes hand in hand with optimized pollution control and lower emissions of the greenhouse gas CO2.

With the DIWA automatic transmission, Voith Turbo is making a significant contribution towards economical driveline concepts. The newly developed gear-shifting program SensoTop utilizes potentials that cannot be unlocked by other gearshifting strategies. SensoTop builds on three complementary dimensions: acceleration-dependent shifting point calculation, the evaluation of driving dynamics and precise topography information from the new, integrated inclination sensor.

The combination of these factors makes sure that the system always finds the optimum gear-shifting speed for absolutely any topography and vehicle load situation. By moving the gear-shifting points into the lower speed range, SensoTop also contributes towards the reduction of noise emissions. The reliable proof of the consumption advantages of SensoTop under real operating conditions was an important building block of the introduction process. In cooperation with leading OEMs, the Voith experts selected a field test program that covered a broad spectrum of topographical and traffic situations. Another challenge was to confirm the consistency of fuel savings across several months. Among the cities selected for proving the SensoTop consumption advantages in applications with flat topography were Munich and Berlin, where continuous field tests were carried out. In both cities, SensoTop competed against the conventional fuel-efficient serial gear-shifting program “Economy Flat”. During such flat applications with few upward or downward gradients, gear-shifting speeds are reduced to the technically possible minimum. The result of approximately two percent less fuel consumption impressively confirms the SensoTop savings potential also in cities with easy topographies. In contrast, field test applications in cit-

ies such as Zurich, Brescia or Würzburg are characterized by demanding, hilly topographies. On upward gradients, SensoTop automatically had to provide the required power, to instantly select optimum gear-shifting curves and to prevent gear hunting. The continuous evaluation of the DIWA operating data has shown that the full-load and kick-down shares of the field test vehicles were significantly reduced after activation of SensoTop. The field test results are impressive: in Würzburg, the SensoTop consumption advantage was in the region of three percent, in Zurich, consumption was reduced by up to five percent, and in Brescia in Italy, the field test vehicles needed up to seven percent less fuel than identical vehicles with the conventional serial gear-shifting program. In field tests in cities with mixed topographical conditions, the Voith team also came up with positive results: in Heidenheim, four percent lower fuel savings could be proven on average.

In Newcastle, Stagecoach vehicles with SensoTop consumed five percent less diesel. The positive conclusion from the continuous field tests will now be followed by the market introduction. The topography-dependent gear-shifting program SensoTop creates added value for vehicle manufacturers and operators – and thus also more value for our environment.

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Reorientation of brakes business The publicly traded construction group, announced yesterday that it had successfully closed the negotiation for the As already announced in the spring, the Bosch Group is reorienting its activities in the Chassis Systems Brakes division. Its foundation brakes business in North America is to be sold to the Japanese brake manufacturer Akebono Brake Industry, Tokyo. Agreements to this effect have now been signed in New York City. The planned takeover includes the business with products such as brake calipers, disc brakes, and drum brakes. The total sales volume involved comes to 580 million dollars in 2009. “In selling our North American foundation brakes business to Akebono, we have found an experienced, internationally active, and strategically oriented brake manufacturer,” said Bernd Bohr, the Bosch board of management member responsible for the Automotive Technology business sector. It is planned to transfer manufacturing sites in Clarksville (TN) and Columbia (SC), as well as certain assets and administrative functions currently located in six further North American locations to Akebono. Bosch had announced its intention to reorient its brake business as early as its annual press conference in spring 2009. Bosch will continue to carry out its own restructuring which includes the potential closure of the manufacturing site in Johnson City (TN) as well as the closure of Knoxville (TN) as already announced. The reorientation that has now begun does not affect Bosch brake activities in the field of brake boosters and commercial vehicles, nor does it affect the ESP and ABS business of the Chassis Systems Control division or the aftermarket business with friction and brake components.

Investing in the growing market for automotive glazing

Bayer MaterialScience has invested heavily in facilities to develop technologies for polycarbonate automotive glazing. The company believes this market to have excellent growth perspectives. With its Makrolon® product brand, Bayer MaterialScience is regarded as one of the world’s leading pioneers in this high-tech application. For example, a fully automated injection molding machine has been installed at the technical service center in Leverkusen that is capable of producing 3D roof modules measuring up to 1.2 square meters along with other complex glazing components. The new equipment enables the company to support its customers along the entire process chain for polycarbonate automotive glazing. Bayer MaterialScience has also expanded its large technical service center for coatings at the Krefeld-Uerdingen site, where experts are currently working to evaluate the abrasion and scratch resistance of coatings for future use in polycarbonate rear windows.

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News 2009-10-06 21:45:28

NEWS

Sustainability: Henkel’s leading position confirmed

International consumer goods manufacturer Henkel has once again been included as a leader in its sector in the Dow Jones Sustainability World Index.

The Index lists corporations that follow the principles of sustainable development in their business operations. Henkel’s sustainability strategy leads the field internationally, as has now been confirmed by its renewed inclusion in the FMCG market segment of the Dow Jones Sustainability World Index (DJSI World). Only 10 percent of the world’s 2,500 largest companies make the grade for inclusion in the DJSI World. For ten years, SAM Indexes GmbH has been assessing companies for the annual listing according to stipulated economic, ecological and social criteria.“We are delighted to receive this international recognition for our sustainability strategy,” says Kasper Rorsted, Chairman of the Henkel Management Board. “In difficult economic times, it is more important than ever to recognize sustainable development for the opportunities that it brings. We see enormous potential for innovations that combine performance

and quality with responsibility toward people and the environment. It is our objective to position Henkel as a leading sustainability partner for our industrial customers, the retail trade and consumers alike.” And Henkel is enjoying success in the pursuit of this objective. For its achievements in operating on a sustainable and socially responsible basis are repeatedly judged to be excellent, not only by numerous national and international ranking agencies but also by the company’s customers. In its “Corporate Responsibility Rating”, for example, oekom research AG reaffirmed Henkel in August 2009 as one of the leading companies in the consumer goods industry.

In China, the Business Watch Magazine also lists Henkel in its current ranking of the ten top performers among “China’s 50 Green Companies”. And in August 2009, Henkel won further recognition from a US customer in the form of the “Kellogg’s Sustainability Challenge” following the conferral by retail giant Wal-Mart on Henkel of the “Wal-Mart Sustainability Award” in March 2009.

Cargill and Hojiblanca inaugurate olive oil bottling plant in Spain Cargill and Hojiblanca have inaugurated a new oil bottling plant at Antequera, near Malaga. The 50/50 joint venture between the companies under the name of Mercaóleo represents an investment of €18 million in the plant itself, in addition to the working capital required to operate at full capacity. The oil bottled will be sold and distributed to customers by its parent companies. The state-of-the -art, highly automated facility has the ability to bottle more than 100 million litres of olive oil annually, with the potential to increase capacity through future expansion. The plant will be bottling a whole range of high quality olive oils in a variety of sizes to meet the needs

of customers globally. Olive oil demand continues to grow across the world due to its unique taste, premium quality and healthy profile. Mercaóleo will produce private label olive oil using the highest quality raw materials, backed by the most advanced bottling practices and capabilities to serve Hojiblanca’s and Cargill’s customers. This plant is a sign of its parent companies’ goal to become leaders in both the European and worldwide private label olive oil markets. Together the two companies will provide clients with expertise on all aspects of the process, from tree to table. „Mercaóleo brings together two compelling sets of capabilities”, said Stan Ryan, head of

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Cargill’s refined oils business in Europe. „Hojiblanca truly understands olive oil and provides reliability, quality and access to large volumes. Meanwhile, Cargill brings production technology and risk management expertise, and a vast global trade, distribution and export network. As well as opening up new, international markets for olive oil, this joint venture highlights Cargill’s commitment to long-term growth and investment opportunities within Spain. This exciting venture should create the best private label olive oil supply chain in the world.” For Hojiblanca this alliance will strengthen its position in the global olive oil sector - accessing new opportunities as the international market for their product grows. „Hojiblanca is the world’s largest producer of olive oil and market leader in Spain for extra-virgin olive and higher quality oils”, said Jose Moreno, Hojiblanca’s president. „Together we will work to enhance the development and growth of a healthy product like virgin olive oil. Thousands of families are depending on this joint venture, so the relationship between the partners is very important. We have a strong belief that our future is going to be improved because of the relationship with Cargill.”

This project will allow the two companies to market a high quality range of private label olive oils to existing and new customers, offering them the opportunity to retail products that are tailor-made to their requirements. Strengthening its involvement in high premium olive oil will complement Cargill’s existing oil offering to customers that in volume terms has focused on many oils, such as sunflower, rapeseed, soya, corn and palm, among others. Cargill currently bottles olive oil at its plants in Seville, Spain and Izegem, Belgium. The company also distributes to customers across Europe, Asia and the Americas. Hojiblanca currently exports high premium olive oil worldwide and also produces and markets table olives. The company will continue to work with farmers and cooperatives to produce large volumes of high quality olive oil. The new bottling facility already has about 20 employees and will create further employment opportunities for production, quality, logistical and financial specialists with proven experience in manufacturing.

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C PR OU O NT FI RY LE

France

Full name: French Republic Population: 61.9 million (UN, 2008) Capital: Paris Area: 543,965 sq km (210,026 sq miles) Major language: French Major religion: Christianity Life expectancy: 77 years (men), 84 years (women) (UN) Monetary unit: 1 euro = 100 cents Main exports: Machinery and transport equipment, agricultural products, including wine GNI per capita: US $38,500 (World Bank, 2007) Internet domain: .fr International dialling code: +33 A key player on the world stage and a country at the political heart of Europe, France paid a high price in both economic and human terms during the two world wars. The years which followed saw protracted conflicts culminating in independence for Algeria and most other French colonies in Africa as well as decolonisation in south-east Asia.

Overview

France was one of the founding fathers of European integration as the continent sought to rebuild after the devastation of World War II. In the 1990s FrancoGerman cooperation was central to European economic integration. The bond between the two countries was again to the fore in the new millennium when their leaders voiced strong opposition as the US-led campaign in Iraq began. But France sent shockwaves

through European Union capitals when its voters rejected the proposed EU constitution in a referendum in May 2005. France’s colonial past is a major contributing factor in the presence of a richly diverse multicultural population. It is home to more than five million people of Arab and African descent. It has a number of territories overseas which, together with mainland France and Corsica, go to make up the 26 regions which the country comprises. It is further divided into 100 departements, four of which - French Guiana, Guadeloupe, Martinique and Réunion are geographically distant from Europe.

Government in France is known for its high degree of centralisation but in March 2003 parliament approved amendments to the constitution allowing for the devolution of quite wide-ranging powers to the regions and departements. In the light of low election turnout, the move was widely

seen as a bid to re-engage in the political process French people disillusioned by the ubiquitous influence of what is often perceived as the Paris elite. France has produced some of the continent’s most influential writers and thinkers from Descartes and Pascal in the 17th century, through Rousseau and Voltaire in the 18th, Baudelaire and Flaubert in the 19th to Sartre and Camus in the 20th.

In the last two centuries it has given the art world the works of Renoir, Monet, Cezanne, Gauguin, Matisse and Braque, to name but a few. It is also famous for its strong culinary tradition. France produces more than 250 cheeses and some of the world’s best-loved wines.

Leaders

The Palace of Versailles

President: Nicolas Sarkozy Nicolas Sarkozy, from the ruling, conservative UMP, won a decisive victory in the second round of the presidential election in May 2007. The key promise on which he fought his election campaign was the introduction of pro-market reforms to tackle sluggish economic growth and high unemployment. He vowed to cut taxes and rein in powerful trades unions. This process began with the September 2007

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Country Profile 2009-10-06 21:45:31

Saint Louis’ Sainte Chapelle

cultivated close ties with US President George W. Bush and has made no secret of his admiration for Bush’s successor, Barack Obama. Nicolas Sarkozy, who was 52 when he was elected, is the son of a Hungarian immigrant and a French mother of Greek Jewish origin.

He grew up in Paris. Thrice married, he has three children. His predecessor, Jacques Chirac, had held office since 1995. French presidents are elected to five-year terms. A candidate can win in one round if he or she secures an absolute majority. Otherwise, the top two candidates go through to a second round. The president, who exercises executive power, appoints a Council of Ministers headed by the prime minister.

The Eiffel Tower

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COUNTRY PROFILE

budget, in which French employers were offered incentives to allow workers to do overtime; there were also tax cuts for high earners. This came just days after Prime Minister Francois Fillon said France was „bankrupt”.

The implementation of Mr Sarkozy’s policies was bound to hit public sector workers hard, and in November 2007 hundreds of thousands of civil servants, transport and energy workers staged industrial action in protest at planned cuts to pay and pension benefits. On foreign policy, Mr Sarkozy has singled out France’s role in Europe as a priority.

He has campaigned vigorously for ratification of the Lisbon Treaty, which was intended to replace the draft EU constitution rejected by French voters in 2005. France took over the EU’s sixmonth rotating presidency in July 2008, and Mr Sarkozy set himself the tricky task of salvaging the Lisbon Treaty after it had been rejected by Irish voters in a referendum in June. Just over a month into France’s EU presidency, Mr Sarkozy’s diplomatic skills were put to a stiff test when conflict broke out between Russia and Georgia in August 2008. Acting in Europe’s name, he took centre-stage in securing a ceasefire - a feat hailed as a big diplomatic success. He has also taken a lead in calling for fundamental reform of the world’s financial system in response to the global credit crunch.

He is seen as being more pro-American than previous French presidents. He

Media

France enjoys a free press and has more than 100 daily newspapers.

Most of them are in private hands and are not linked to political parties.

Public broadcaster Radio France runs services for the domestic audience, French overseas territories and foreign audiences. Radio France Internationale is one of the world’s leading international stations. Its Arabic-language Monte Carlo International service is available on mediumwave (AM) and FM in many Middle East countries. The international French-language channel TV5 Monde, financed by Belgium, Canada and Switzerland, is available globally. Global satellite news channel France 24 launched in December 2006 with services in French and English.

Its chairman said the channel aimed to present „a different point of view from the Anglo-Saxon world”. France’s flagship TV station, TF1, was privatised in 1987. The growth of satellite and cable has led to a proliferation of channels. Major satellite pay-TV operator CanalSatellite is controlled by media giant Vivendi Universal. A digital terrestrial TV service, with more than a dozen free-to-air channels, is being rolled out. France’s long-established commercial radio stations, particularly RTL and Europe 1, still command large audiences. They have been joined by a multiplicity of FM stations, often consolidated into successful commercial networks such as hit music station NRJ and oldies station Nostalgie.

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THE PARTNER TO RELY ON

FACT BOX FULL NAME: Fabryka Galanterii Czekoladowej EDBOL Bogusław Dudziński PRESIDENT: Bogusław Dudziński -owner OPERATIONS: production and distribution of sweets ESTABLISHED: 1980 EMPLOYEES: 198

www.edbol.pl

E

dbol, The Confectionery Factory located in Bydgoszcz, Poland, has been manufacturing chocolate products for nearly thirty years.

As the company primarily focuses on the relationship marketing, its wide assortment of high quality confectionery can be purchased under the own label brands offered by supermarket chains.

The corporations which Edbol trades with have thus recognized the firm as a reliable business partner.

Since its inception in 1980 Edbol has been a family business. Set up by Mr Bogusław Dudziński and run with his two sons, it entered the market as a small factory making patisseries and products coated with choc-

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olate. The growth of the business picked up the pace at the end of 1980’s, which coincided with the political and economical transformation that took place in Poland at the time. From then on the firm has perceptibly expanded, having developed and improved its machine park including efficient and modern production lines. Nowadays it comprises three independent confectionery plants specializing in the production of candied fruit and nuts encrusted with chocolate, chocolate bars and, finally, wafer rolls. These three plants are capable of turning out the amount of goods reaching 8.000 tones every year. The size of the factory and scope of its production proves a remarkable achievement, indeed, if compared to its modest beginnings in the hard times of early 1980’s.

The company’s success would not be at all possible if it had not been for the business principles laid

down by the owners and further applied by the management. These are founded upon two pillars – partnership and quality. Firstly, Edbol considers itself a part of a wide global network of producers and retailers; hence the emphasis on respect and making good relationships with business partners.

At the same time, The Factory finds its mission in taking care about the steady and high quality of products which are able to meet the requirements of most choosy clientele. For it is the satisfaction and pleasure that customers derive from the Edbol confectionery that matter for Mr Dudziński and his sons.

Decisive moments

Initially, the company concentrated on the local market selling its confectionery under Prima label brand. As the Edbol sales manager, Mrs Beata Kowalska, recounts “The Factory operated accordingly until the year 2002.” Nevertheless, the rapidly changing market economy challenged the profile of the business and consequently reshaped it. Since customers were tightening their belts, the industry came in for fierce competition. Hence Mrs Kowalska adds: “In those days, namely at the turn of 2002 and 2003, the watershed in the company’s marketing strategy came about.

It was the time of economic slump and our prospective clients were in favour

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of affordable price over supreme standard. Moreover, many average size businesses experienced difficulty marketing stuff of nonetheless considerable quality. Working under such unfavourable conditions, we decided to implement a new policy.” What was their recipe for success? The business underwent a fundamental change in order to establish close marketing relationship with retail corporations. Thus, it became a part of the global network. It marks the turning point in the history of the company. Mrs Kowalska sums it up as follows: “Having drawn on the experience of the producers from Western Europe, we launched the branch of production which would cater to the orders of supermarket chains selling our goods under their own label brand. Consequently, we set our business objective which was to persuade the consumer that the own label brand does not necessarily amount to poor quality. It took several years to fulfil it.” Unknown though the future was, to establish liaison with corporate retailers proved an unprecedented success for Mr Dudziński’s business. Little wonder, therefore, that the own label brand production contributes to 90% of the revenue that Edbol generates at the present time. Another decisive moment on the track record of Edbol goes back to Poland’s accession to the European Union. The European markets being finally open to Polish commodities gave its manufacturers a unique chance to prove the passion, resourcefulness and honesty they put in the process of production. The visit of the representatives of Kesco Food Finland to Edbol’s headquarters in Bydgoszcz in 2005 was a case in point. On that special occasion the company launched a brand new product for their Finnish partners, namely royal raisins encrusted with chocolate.

Mrs Kowalska recalls the event and its positive implications: “The appreciation on the part of our Finnish business partners gave us a real boost. From then on we found ourselves skilled, courageous and independent enough to proceed with our dealings on the rapidly expanding market. We had never experienced such an invigorating feeling before.”

A part of a network

A switch to relationship marketing resulted in cooperation with retail giants, Thus, The Factory derives satisfaction from manufacturing and supplying its goods to business associates accord-

ing to their most specific requirements.

Once being a local competitor, Edbol has partaken of a wide business network and as a result become a producer enjoying international recognition. It has made its mark catering to corporate partners such as: Biedronka (part of Jeronimo Martins Corporation), Carrefour, Tradis (formerly Eldorado), Lewiatan Holding S.A., Polomarket, Auchan, Netto, Tesco, Żabka, Intermarche, Dino Markets, Kesco Food Finland. Among retail giants the Polish branch of Carrefour chain emerges to be of utmost importance to the company’s marketing strategy. While Edbol maintains a good liaison with the corporation providing it with thirteen various quality products, Carrefour sells these further under its own label brand. The Factory takes particular pride in being invited by the business partner to participate in the conference held in 2007 related to the rising significance and growing power of own label brands. The company was presented there to the public as a dynamic

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producer of own label brands whose quality had earned the consumers’ recognition and trust. It all goes to show that hard work combined with careful planning and quality kept in check may be as crucial to commercial success as aggressive advertising campaigns. At present, export production makes up to 12% of the company’s turnover whereas in 2005 it amounted to only 2%. While

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Quality on top

Edbol’s trustworthiness and commitment have been acknowledged by many foreign markets, the company itself concentrates on maintaining good business relations with consumers in such countries as Canada, Austria, Germany and UK, alongside with Israel, Italy, Portugal, Czech Republic and Slovakia. Furthermore, Edbol can boast its own independent distributing branch in Hungary. The confectionery produced by the factory also complies with all the conditions of kosherness, which is considered a must for foodstuff producers desiring to attract Jewish clientele in Israel and elsewhere. It meets the requirements of halal certificate, too, thus making it available to a vast number of Muslim consumers and opening a range of business opportunities not merely confined to European markets.

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As a supplier of retail leaders Edbol is chiefly recognised for its delicious whole nut chocolate bars.

The company also specialises in the production of candied fruit encrusted with milk, white and dark chocolate.

The factory’s offer includes wafer rolls with filling coated with chocolate, too. In addition, there are products of prime quality to be found in Edbol’s portfolio, such as cherries, cranberries and gooseberries encrusted with chocolate. Nonetheless, the business takes particular pride in products sold under the family brand Amadeo.

It has been steadily earning the good name among individual clientele as a good value for money type of label.

Edbol takes extreme care to be up to date on the needs and opinions of final consumers. Thus, the company’s representatives monitor customer panel discussions, familiarize themselves with the latest trends and react to them accordingly. The business also participates in the international expositions such as “PLMA’s World of Private Label” Trade Show in Amsterdam, Holland, and ISM Trade Show in Köln, Germany. It is also a member of Polbisco, The Polish Chocolate and Confectionery Producers Association, which gathers the most conscientious competitors in the industry. Mrs Kowalska adds: “We firmly believe that since our hard work results in high qual-

ity of our products, we will live up to the expectations of contemporary customers.” In order to keep on top of quality and to increase efficiency as well Edbol has taken advantage of modern technology. Hence a machine park newly developed and improved. By the end of 2009 there will have been the chocolate drops section extended and its capacity of 100 tones per year quadrupled.

The business is also planning to revamp the production lines so as to meet the growing demand for prime quality confectionery. The company has changed its location too. Currently the factory takes up the area of 10 ha, 6230 sqm of which is occupied by production space.

The integrated managing systems of ISO 9001 and HACCP have been implemented there, too, which enabled to optimise all the processes going on in the firm. Moreover, Edbol adheres to the requirements of BRC Certificate and is currently working on the project which will make it comply with the standards of ISO 22000. Mrs Kowalska says: “There is every likelihood that we will accomplish our tasks by the end of 2009. We hope that our efforts will result in the stable increase in sales. It is a final proof that one is worthy of the consumers’ trust.”

The human factor

A part of the global network as it is, Edbol has primarily remained a family business. In addition, the company is involved in the sheltered employment scheme. Since it has proved a winning combination, the company attaches great importance to the human factor in the creation of steady and friendly working environment. Consequently, the issues of interpersonal relations, work satisfaction and work-life balance among the employees are genuinely scrutinized and duly addressed by the supervisors.

Mrs Kowalska asserts: “What distinguishes us from other competitors is that we have regard for our staff. Since there is no rigid hierarchy within the company, they benefit from direct access to the management who is always willing to lend an ear to their problems and suggestions. We appreciate hard work and dedication.” That seems yet another aspect essential for the establishment of a credible business such as Edbol. The soft management methods applied by its owners and supervisors bear it out perfectly that the ordinary workers may contribute to and profit from the global network hand in hand with final consumers, retailers and producers.

Food&Beverage Industry > Edbol 2009-10-06 21:45:38

FULL NAME: Closed Joint-Stock Company “Moscow Brewery and Beverages Factory “Ochakovo” PRESIDENT: Aleksey Andreevich Kochetov OPERATIONS: Production of beer, alcoholic and nonalcoholic beverages ESTABLISHED: 1978 EMPLOYEES: 2500

www.ochakovo.ru

F

irst Ochakovo TM appeared on a market in the end of 1970s, as opening of production was confined to Olympic Games of Ochakovo President 1980. Since then Aleksey Kochetov Ochakovo estimates the constant growth of influence on the market and today is one of the major producers of beer and other beverages in Russia. Moreover, the company is the only large player without foreign ownership and its products are in high demand.

wery industry – the last that has so far resisted being taken over by foreign or domestic giants). Soon the enterprise provided an impetus to formation of the biggest in Russia for production of beer, low alcoholic and soft drinks. In the end of the 1990s the next stage of development begun – that period was marked with implementation of new long-term comprehensive programme implying modernization of the enterprise and diversification. Just after that, another important decision was made. Company’s authorities ordered an expansion of the new acquired plant and a simultaneous adaptation to the strict European standards and requirements. In 2000 factory

in Krasnodar, down on the Black Sea, was open. The factory came out on the European level, as the modern equipment was supplied by German, Italian, French and Belgian companies. In 2003 plant in Penza, in central Russia, was put into the operation. At first low-alcoholic and non-alcoholic drinks were produced there.

Two years later beer was manufactured as well. The same year new malthouse in the Lipetsk region was established. Perfect technologies of production and careful selection of barley enabled to produce the malt of the highest quality. In 2007 work began on a third brewery, in the Siberian city of Tumen. Today CJSM Ochakovo is one of the modern enter-

TRADITIONAL RUSSIAN DRINKS AND COUNTRY’S PRIDE

FACT BOX

The first factory was established in 1978 giving start to the company, which turned into biggest company in Russia. The first beer and soft-drink plant was built prior to the Olympics of 1980 in Moscow, in order to provide guests and participants with beer and soft drinks.

Initially the factory produced beer only: Stolichnoye, Zhigulevskoye, Yachmenny kolos. But then, in 1979, the new equipment was installed to bottle soft drinks and thereby every needs of capital’s inhabitants and guests could be satisfied.

In 1993 important changes were brought to the factory – it was reorganized into a closed joint stock company, without a foreign shareholder (Ochakovo remains the only thoroughly Russian company among its competitors in bre-

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prises in Russia and Europe. The company is true to the high standards of production. In addition to operating its main brewery in Moscow, Ochakovo controls over 20 enterprises including breweries, a winery, malt complexes and agricultural enterprises all over Russia. However, they could not be properly carried out without the human crew.

At the moment Ochakovo employs over 3 500 workers, who help and give their best in the daily production process. The mission of the company is clearly defined as taking care of the health of Russian people and providing them with high-quality and natural drinks, without preservatives and synthetic additives.

Company’s president Aleksey Kochetov declared the Ochakovo is duty bound to stand for Russia’s interest and aspires to be one of the country’s brightest representatives on the local and foreign markets. As the company’s authorities emphasized, Ochakovo being wholly Russian-owned company doesn’t pay dividends and all the revenue is allocated on investments. In terms of bitter competition on Russian market, Ochakovo intends to capitalize on its diversity. The company produces eight groups of beverages with more than 100 brands. Beside beer it produces vodka, liqueurs, wines, alcohol cocktails, kvass, mineral waters, soft drinks and low-alcohol drinks.

Apart from that funds are assigned to constant updating of production technologies, logistics optimization and distribution technologies. The priority is given to launching new brands as well.

A boom in a traditional

Russian peasant brew - strategic capability

dramatically over the last few years, with a clear shift away from vodka towards “lighter” alcoholic beverages such as beer and wine. This has seen increasing numbers of imported wines on Russian shelves, but has also led to burgeoning revival of the domestic wine industry. Ochakovo has launched itself into the wine market in an ambitious move to revive the great tradition of the country’s wine industry. In 2000 Southern Wine Company (SWC), Ochakovo’s subsidiary was created. The place was chosen not accidentally – Taman Peninsula was in the 19th century the centre of Russian winemaking. The region is famous with a large number of warm, sunny days which help grapes to ripen, while the mild winters allow them to escape the rigours of snow and frost. With regard to beer and soft drinks sector, Ochakovo is already among the biggest players. The compa-

ny wants to repeat its success in the wine industry. It is worth to notice, that it was starting from nothing. Simply, the company puts every effort to harmonize the modern technology of production with the traditional Russian taste. It also has a great potential for answering on every new customer’s requests and needs.

Most recognised brands

Some drinks should be mentioned separately. For example, Ochakovo beer that is considered to be the main and well-known brand of the company. It has maintained leading position on domestic market for the last 15 years. Company benefits from strong brand recognition and trust. Ochakovo remains also one of the major producer of kvass. Kvass Ochakovskiy, that is preparing with unique technologies, enjoys the unstinting popularity among Rus-

Like many Russian companies, Ochakovo, which prides itself on being entirely Russian-owned since its creation, has seized on a revival in Russian nationalism to push its product. That is why the company launched to the market products such as: traditional Russian medovukha (honey vodka), traditional kvass (a national speciality made from fermented rye bread) and kvass with horseradish.

Ochakovo’s specialists prepared also kvass for kids: Kvassionok, which unlike western lemonade is produced without sugar, coloring and preservatives. Today Ochakovo is the leading player on the rapidly growing Russian kvass market.

The company ensure that an authentic peasant recipe are using to prepare traditional drinks. Noteworthy, that Russian consumption patterns have changed

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sian and foreign consumers. Its high quality was confirmed by the Russian Academy of Agricultural Sciences. The company boasts with providing its clients with wine cocktails, that are unique on the Russian market – this wine-based low-alcohol drinks are prepared without any preservatives and take the sophisticated flavour of wine. Ochakovo’s wines (Chardonnay and Cabernet) and wine-based drinks (Kryushon Ochakovsky white) have achieved numerous medals during consumer’s tasting.

Company’s achievements

Thanks to the passion and hard work, the company have achieved a lot of proves of its high status and European standard, under the form of the International quality certificates. Ochakovo’s products have been as well the laureates of many food competitions. Every year the beer

Ochakovo is awarded during consumer’s tasting at The Big Moscow Beer Festival, where selection of world’s finest brews is represented. Ochakovo’s soft drink Gintonic several times has been announced “Product of the Year”. Participation in the PRODEXPO, the largest annual specialized exhibition in Russia and Eastern Europe brought to Ochakovo’s products several prizes. The Ochakovo pride is the international prize “European Standard” that the company was awarded in 2005 – it is the best confirmation that company’s products meet the rigid European requirements. In 2006 Ochakovo was hailed “The biggest tax payer of the year”, that means that Ochakovo successfully contributes to country’s welfare. In 2008 in turn, the company won the title of “The best Russian exporter” in a category of alcoholic and non-alcoholic drinks. That is only a part of prizes and

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certificates that Ochakovo was awarded.

Recently, “Ochakovo Museum” – a museum dedicated to traditional national drinks, located in the factory of Ochakovo in Moscow – was opened. A museum containing a unique collection of more then 300 exhibits on the history of beer, Russian brewing traditions from the 17th century and drinking culture.

Visitors could observe how the centuries-old beverage, kvass, is fermented from rye or survey the every stage of beer production. The idea of the museum

Market positions

Ochakovo is known and appreciated first and foremost due to Ochakovo beer. The volume of sales of beer make 70% of total volume and company’s production capacity is dedicated first off all to beer production. But Ochakovo is not simply the manufacturer of beer, but is focused on fulfillment of expectations of customers in different segments as well, such as: wines, mineral waters, vodka, non-alcoholic drinks and then some. In 2008 beer sales volumes increased by 12%, low-alcoholic coctails – by 6% and kvass – by 2%. Furthermore, Ochakovo managed to strengthen its market positions in far remote regions of the country, in which sales volumes increased by 5.5%. The Ochakovo’s drinks are sold all over the world. The inimitable flavour of its beer and other products is known in countries, such as: Germany, Greece, USA, Japan, Korea, Georgia, Lithuania etc. Exports geography is constantly broadening. Annually exports volumes increases by about 40%. Most of foreign partners are making contracts for supplies of kvass and beer.

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2010 the company is planning to open a new factory in the village of Vall de Bianya. In new facilities the workers will dedicate to the production of a new range of products called “Tapas al Minuto”. These products, launched on the market in 2002, turned out to be successful, not only on the national market but also in the area of exportation. Esteban Espuña is particularly devoted to production and marketing of pork meats, with turnover which in 2008 amounted to 86,8 million euro. The value of exportation comes almost to 25 % of total revenue of the enterprise. Nowadays the export is still widening and the presence of the company on different foreign markets is still increasing; hovewer, the most important destinations remain: France with more than 40 % of the total turnover from exportation, Portugal and Great Britain (20 %) as well as Germany (5 %). The production plant located in Argentina will surely allow the company to cover the needs of American market.

Principles of the enterprise operating on nutritional market

Quality from experience patient work it is impossible to succeed.

E

A glance at factors

In order to achieve these goals, Espuña uses the following procedures: selection of the finest raw materials, the most rigorous monitoring and hygiene systems in production, the latest technological solutions. The production is supported by the philosophy that without meticulous and

The company Espuña was established in 1947 by Esteve Espuña in a village Vall de Bianya (in the region of Girona, Catalonia, Spain). The year 1949 witnessed the relocation of the enterprise to Olot (a small town in Catalonia), where nowadays still operates its headquarters. Currently, the Espuña family controls 100% of the capital of the company Esteban Espuña, with the staff of 480 employees.

It is worth emphasizing that the company disposes of industrial area equivalent to 43.348 m2 divided in four production plants. Two of them are located in Olot, one in Utrillas (Teruel) and the last one in Argentina. It is already known that in

steban Espuña is the company operating for more than fifty years in the sector of nutritional production, especially in the field of pork products. Its traditon has been developed in one of key places of Catalan cuisine – a small town Olot in the foothills of the Pyrenees. Since the beginning of its activity on the market, the enterprise has pointed at gaining the best quality by bringing together traditional knowledge and the most innovative technological processes.

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favourable to success

The philosophy which lies on the basis of the company is very coherent and keeps pace with a rush of recent times. It has to be enhanced that a constant lack of time traces new lifestyles and creates new needs of consumers, especially in the area of nutrition. That is the reason why the consumers put more and more attention to ready-made and tasty products prepared to direct consumption. In order to respond to this demand Espuña proposes a various range of cold meats, snacks (famous Spanish tapas) and sliced products. The company is always working on improving the products as well as ist packaging in order to satisfy emerging needs of the market. “Innovation, quality and nutritional security” – in according to these main principles the enterprise runs its activity.

Innovation as a key for future

As it has been mentioned, the innovation is one of the key values for Espuña, especially for its future growth. Having in mind these aims, at the end of 2003 it introduced an internal program, called Espuña Innova, in which participated every employee of the company, contributing

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with innovative ideas related to products and processes. The project has already brought successful effects. As a result of collaboration between staff members and of brainstorming which generated a lot of ideas it was created a new product, awarded with the prize for “The Product of Year 2009”. Following this direction, the company understands importance of investments in improving the quality – it assigns a lot of resources to innovate technology, which could increase added value of its products. There are few examples of implementation of new technology solutions, noticed in the area of sliced products. It was introduced the method called “cold pasteurization”, which ensures the freshness of cooked products and allows to offer a range of sliced products (ham, cold meats and sausages) which can be conserved in room temperature. Another important technological convenience is traceability of dry-cured ham. This service, offered on the web site of the company, is available for everyone who wants to know the origin of the meat. The process allows a consumer to follow the trail of each slice of Espuña dry-cured ham from its origin until the moment when it is purchased by a customer. By rapidly introducing a single number code found on the slice separating film it can be discovered the evolution of the product during the entire food chain, from the farm where the pigs are fattened to the slaughterhouse, the curing plant, the packing centre and the slicing plant.

A range of products

Espuña makes a great effort in order to ensure an appropriate process of produc-

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tion, because the method that is used allows to single out every product, which determines the personality of the company. The wide range of Espuña products differs from: dry-cured and cooked ham, sliced products, sausages, bacon, cold meats, minute tapas (snacks) to sliced tapas. Every product is looked after carefully, which singles it out from others. For instance in production of sausages there are used traditional recipies combined with an apropriate process of drying, which gives to the product a particular flavour. Other product, a serrano ham (a very important ingredient of a Mediterranean cuisine) is based on the finest meat, a proper amount of salt and a balanced process of dry-curing (which at Espuña never lasts less than 8 months).

Going into details, we can see that also other products build up the prestige of the company, like bacon prepared or a cooked ham, produced from chosen meat and by using the most advanced technology. Also taking into consideration cold meats it can be noticed that there are used traditional recipes and techniques together with the most up to date production methods. According to its philosophy, Espuña invests also in sliced products in order to reach consumers who always want to save time.

That is why it created sliced products as: serrano ham, sausages, cooked ham, strips, delicatessen products, turkey, bacon and cold meats. The company invests also in packaging, which ensure the highest standard of hygiene as well as is colorful and attractive. In order to reach the consumer in even more direct way, the enterprise introduced the products whose packagings fulfil particular needs, for example: trays for family or individual use and gift boxes with attractive packaging. The same philosophy

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of saving time was the basis for a new line of Minute tapas – a range of 10 different snacks – which can be warmed up in the microwave in one minute.

Response to emerging consumers’ needs

Within the range of sliced food the company Espuña launches new products always with the object of innovating the packaging in order to make it more practical for consumers. Taking into consideration the fact that consumers’ needs are changing, the company developed new tastes within the range “Tapas al Minuto” by mixing two recipies. The enterprise also created a new product – Surtido (Assorted) Tapas al Minuto, the winner of the prize “The Product of Year 2009”. All innovations described above reflect reactions to tendencies present on the changing market. By offering convenient products Espuña responds to the problem of “lack of time” and by offering tasty products of good quality fulfils “need of pleasure”.

Confirmation of

consumers’ confidence

The efforts of Espuña towards innovation, high quality and satysfying consumers’ needs have been appreciated. In 2009 the consumers awarded Surtido de Tapas al Minuto with the title of the Best Product of Year 2009 in category of ready-made dishes. It reflects a good reaction of the company which responds to expectations of the market – a product perfect for eating at home among friends or family. It can be prepared in very fast and easy way by putting it directly into microvawe, without dirtying pots. The product is ready in two minutes. Consumers showed their confi-

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dence towards Espuña also by awarding other product - a ham (Jamón Curado Duro Corte Especial Artesano) with the prize for the Best Product of Year 2009.

The product is presented in a re-closing packaging, very useful in conservation.

Production process

The fact that is worth emphasizing is that the company uses in production the technology of high pressure, which ensures a good conservation of food and at the same time nutritional security. This method doesn’t modify mechanical properties of the product. Espuña’s Sliced Ham, introduced in October 1998, was the first highpressurised meat product in the world.

In February 2002, Espuña introduced a new series of high-pressurised Catalan sausages, pre-cooked brochettes and small chorizos. The process of high pressure packaging consists in immersion of the meat products in water (in their final package). They are put in a tank designed to resist a pressure of 4000 atmospheres, equal to a water pressure that would exist at a depth of 40 km. This procedure avoids the use of heat that could affect the taste, texture or nutritional value of the food. What is more and what really counts for the environment is the fact that treating products with high pressure requires much less energy than most other preservation systems. It only uses electricity and recycled water, and does not produce waste. Reassuming it can be stated that the process of food treatment shows the respect which the company has to its consumers while the constant investments in innovation permit to Espuña to have good perspective for future.

Food & Beverage Industry > Espuña 2009-10-06 21:45:46

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Manufacturing-Journal 23 2009-10-06 21:45:48

Ukrainian Beer No. 1

T

he best beer company in Ukraine “Obolon” is considered to be the leader on local market and one of the brightest representatives of the country on foreign markets as well.

The company defined its mission and consistently sticks to it: “We work every day in order to be the first and not to leave thirsty ones on the planet”.

President of “Obolon” CJSC Oleksandr Slobodyan

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Results speak for themselves. The share of the company in export of Ukrainian beer in 2007 was over 75%. The inimitable flavour of Ukrainian traditions implemented by brewers of “Obolon” is known in over 33 countries of the world. Upon that line of “Obolon” company (beer, low alcoholic and soft drinks and mineral water) occupies leading positions on domestic market. Brands such as “Zhivchik” (a juicy soft drink), beers: “Zibert”, “Obolon”, “Desant”, mineral waters: “Obolonskaya”, “Prozora” or low alcoholic drinks like “Gin-Tonic” or “Brandy-Cola” etc. are familiar to all the Ukrainians and “Obolon” is considered to be the symbol of Ukraine and its national pride. In total forty trademarks of “Obolon” are represented on a market.

When a new brewery was built in Kyiv in 1980, hardly anyone could presume that in three decades this business would be a company of a European quality. Today “Obolon”, a Ukrainian closed jointstock company, belongs to one hundred biggest enterprises of Ukraine. In addition to operating its main brewery in Kyiv, it controls enterprises all over Ukraine. These are the main plant, two subsidiaries and four enterprises with corporate rights. The corporation has

about 6 thousand employees. The biggest “Obolon” brewery is in Kyiv. “Krasilovskoe” subsidiary in Khmelnitsk region produces mineral water, low-alcoholic and soft drinks. At the “Zibert’s Brewery” subsidiary in Fastov new sort of beer “Zibert” TM was launched after a large-scale modernization of the brewery. Enterprises in Sevastopol, Bershad, Akhtyrka and Kolomyia are successful as well. The main plant received its name not at once – only in 1986, and owes

Food & Beverage Industry > Obolon 2009-10-06 21:45:49

it after Kiev city district of the same name. In quarter of a century “Obolon” turned into world-known brand. Today people on five continents associate “Obolon” with Ukrainian beer No. 1.

Expanding the assortment

of “Obolon” products

The key ingredient of the company’s success are modern production technologies, an extended portfolio of brands and a constant launch of new trade marks. The company successfully keeps pace with world trends. The company has experienced several stages of development since the first Obolon TM appeared on a market. Nowadays “Obolon” CJSC launches new trade marks to the market annually. In the summer of 2008 a new soft drink «Frest» and a rebranded «Magnat» trade mark – the first Ukrainian elite beer, were launched. “Magnat” represents a super-premium segment, the dynamic development of which became a stable trend on the market.

This segment remains in the stage of active formation. Having estimated the prospects, “Obolon” offered its consumers its own elite beer. Correlation of the highest quality available in the segment, price and successful positioning allows “Magnat” to occupy a stable position in the super-premium segment. At the beginning of 2009 the national beer brand “Zibert” was launched. The company also presented an innovative product which extended a line called «hike» TM. It is a non-alcoholic beer with the effect of energy drink «hike energy». Another novelty is “Beermix Energy” - the new beer brand, a unique combination of light beer, rich taste of forest berries and energy effect. Recently brewer “Obolon” announced that it has started to export barley malt produced at its new malthouse in the Khmelnitsk region. The malting plant was launched in Chemerivtsi urban-type community at the end of 2008 and is one of the most

Food & Beverage Industry > Obolon Księga1.indb 27

modern malting enterprises in Europe.

The investments made in the project are about 500 million UAH. It is worth to notice that plant was modernizing in the conditions of economical recession, when many enterprises have stopped, so it is recognized as the real victory by company’s management. Owing to the most modern equipment and adoption of the newest production technologies a plant came out on the European level. Perfect technologies of production and careful selection of barley enable to produce the light malt of Pilsner type of the highest quality. Such countries as Slovenia, Russia, Germany and Baltic countries already expressed their willingness in importing barley malt.

Market positions

Exporting tasty and high-quality drinks to 33 countries of the world, “Obolon” strengthened Ukraine’s image as a stable and reliable partner. It is worth to notice that “Obolon” was the first company in the former Soviet Union to export beer abroad. First the taste of Ukrainian beer was presented in United Kingdom.

Expanding the assortment of beer products constantly, the company presents to the admirers of hopped drink the new perfect sorts. In 2008 export volumes increased by 11.4% and amounted to 2.64 millions of hectolitres. In Russia the “Obolon” CJSC products occupied about 2% of the market. In Belarus company’s share on the market was 5%, in import, 20%. The country leading in consumption of Ukrainian beer in 2008 was Moldova, where the market share was 7%. Among three leaders on the domestic market, “Obolon” remains the only thoroughly Ukrainian company. Its share on the Ukrainian market is 30.3%. Correspondingly its competitors’ are: “SUN InBev Ukraine” at 37.4% and “Slavutich”, Carlsberg Group at 23.1%. But according to the volumes of beer production “Obolon” is the obvious leader. The share of the company in structure of produc-

Manufacturing-Journal 25 2009-10-06 21:45:51

Ammonium Removal by CHRIWA Water Treatment in the Chemerovtsi Malt House (Obolon Brewery, Kiev) Nitrification The malt house in Chemerovtsi receives water from 5 own wells.

Amongst other solutes, the water has an elevated content of Iron and Ammonium. The water must be deferrized and treated by a nitrification. The water from the different wells is blended and stored in 2 raw water tanks of 150 m³ each. Raw water pumps convey the water via the CHRIWA water treatment plant to the treated water tank. In winter the raw water is heated up to approx. 10°C upstream of the filter plant. In summer the plate heat exchanger is bypassed. The first stage of the plant is designed as „dry bed“ filters, in which the water is sprayed in the head space

and trickling through the filter bed in co-current with air. Thanks to the intensive air (oxygen) contact a biological film on the filter material is formed. With the help of this natural, desired biofilm the detrimental ammonium in the water is converted via nitrite to nitrate. Simultaneously the iron dissolved in the water is oxidized and converted to iron hydroxide flocks, which are retained by the filter material. CHRIWA is one of the few water treatment companies still being competent in the sensitive ammonium removal by dry bed filters. The secondary filter stage is a conventional immersed bed filtration to remove the residual iron and biomass which may be expelled from the 1st stage. The purified water from the CHRIWA deferrization- and ammonium removal plant is collected in the treated water storage tank for further use in the malt house. Under stable, continuous operating conditions 1 mg/l NH4 (ammonium) is converted to 3,5 mg/l NO3 (nitrate).

Ammonium and Nitrite (NO2) are below the detection limit.

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Food & Beverage Industry > Obolon 2009-10-06 21:45:53

tion according to the results of 2008 increased to 35.4%. (“SUN InBev Ukraine” occupies 34.1 % of the market, “Slavutich”, Carlsberg Group – 22.2%, “Sarmat” – 4.9%). The next step for “Obolon” is leadership in other segments of the market. With regards to soft drinks, “Obolon” occupies the second position on the market (controlling 12,5 % of the market according to results of 2008). Its brand “Zhivchik” (a juicy soft drink containing apple juice, potion of purple Echinacea and vitamin C) is one of the most popular drinks on the market. It occupies 65% of the company’s portfolio, and in soft drinks production in Ukraine its share has achieved 7.8%. One of the main market trends recently was the quick growth of non-alcoholic beer segment – almost by 30% in 2007 and by 21% in 2008.

Sales of this drink in cans grew double within the last year. Taking care of its consumers, “Obolon” company started producing non-alcoholic beer in cans. Since 2008 consumers can also enjoy “Obolon Light” beer in a can.

Keynotes in

marketing strategy

The main forces and funds of the company were always assigned to the production development potential. Only since 2004 special attention has been paid to marketing support of the products and first of all to beer. Within this period, the market share of “Obolon” TM grew from 22.7% in 2004 to 27.6% in 2008. “Obolon” TM’s positioning is “Beer of your Motherland”. In compliance with this concept many clips were shot and dozens of plots for outdoor advertising were created. The key direction of communication of the brand was developing of the “Beer of your Motherland” positioning and measures directed to confirmation of incontestable leadership of “Obolon” TM. It was important to focus attention of the consumers on key values of the brand. In order to bring it, marketing specialists addressed to the feeling of patriotism and pride for Ukraine.

The best reason for pride in this case is “Obolon” beer itself, which is sold in 33 countries of the world. Ukraine is known and respected for the “Obolon” beer, because it is the real Ukrainian taste.

- History of modern Ukrainian brewery started from “Obolon”. Today our trade mark is the incontestable leader on the market.

Slogan “Beer of your Motherland” is the strongest among all beer brands and the most sympathetic to every Ukrainian. – said Olena Garbarchuk, director for sales and marketing at “Obolon”.

Responsible business conduct

With responsible marketing practices, sound environmental decisions and strong community partnerships “Obolon” is the company that represents Ukraine in the world worthily. Upon this “Obolon” steadily observes principles of openness, transparency, consistency, planning and efficiency. Since 1994 “Obolon” is the member of Ukrainian

Food & Beverage Industry > Obolon Księga1.indb 29

Manufacturing-Journal 27 2009-10-06 21:45:55

Quality Association, and since 1998 – member of Club of Quality Leaders of Ukraine. In 2008 “Obolon” CJSC for the first time among the enterprises of food industry certified four management systems at once, in compliance with the requirements of international standards. The company belongs to the biggest tax payers of Kiev and Ukraine and has a reputation of one of the best employers of Ukraine. In 2007 the amount of charged tax deductions was over 700 millions of UAH. The company conducts a responsible social policy. Each employee has the opportunity to get additional professional education. Apart from this, medical survey, provision of first aid, preventive treatment, development of social sphere is provided. In compliance

28 Manufacturing-Journal Księga1.indb 30

with legislative norms about 5% from total amount of employees of “Obolon” JSC are handicapped people. Salary in “Obolon” CJSC is paid timely and annually grows by 10-15%. The company makes every effort to reduce the impact of its operations on the environment. Since 2002 in Aleksandria (in Kirovograd region) an installation for processing PET-bottles with capacity of 500 kg per hour has been functioning. Since 2008 production of rim bands on the ground of processing of PET bottles has been launched there.

In cities of Ukraine, in particular in Kiev, Simferopol, Zaporozhye and Krasilov, containers for separate collection of PET bottles are installed. Upon that the company could boast with a 42% reduction in harmful emissions into the air in recent years. The sum of ecological expenses of the company for the 2008 made more than 5 millions UAH. “Obolon” has been engaged in charity actively for over one and a half decade. This direction of activity of the company is comprehensive and includes: education projects, help to disadvantaged groups, facilitation of re-

vival of spirituality and historic and cultural heritage. Such projects like “Support of Native Cinematograph”, “Children hospital of the future”, “Malovidoma Ukraina” (directed to popularization of travels across Ukraine and support of historic and cultural heritage of our country) are under support of “Obolon” company.

FACT BOX FULL NAME: Obolon CJSC PRESIDENT: Oleksandr Slobodyan OPERATIONS: Production of beer, low-alcoholic and soft drinks, mineral water ESTABLISHED: 1980 EMPLOYEES: 6000 REVENUE: 4,176 bil UAH

www.obolon.com

Food & Beverage Industry > Obolon 2009-10-06 21:45:56

AMBER – the taste of tradition captured in a bottle

I

s there someone who does not think that beer is the most popular and most widely consumed alcoholic beverage in the world?

You don’t need Owner of Brewery Amber to be aware of Andrzej Przybyło the market researches and sale numbers to know that. It is more than obvious. You don’t have to be a beerdrinker or an occasional enthusiast either, to take a right guess. In fact, beer is also an oldest alcoholic beverage. It presents centuries of tradition be counted from the ancient times, and today, more than ever, it constitutes a part of contemporary social culture and somehow even supports human interactions. Poland, as a country with a rich and long-lasting beer tradition, offers not only well-known world brands, but can be proud of a great number of regional specialties. Thanks to AMBER Company, one of the most modern Polish breweries, world consumers have a possibility to get to know and to appreciate several legendary tastes from the Baltic seaside.

Few words about AMBER Brewery itself

The Company AMBER, cultivating regional brewery tradition since years, is located in the midst of moraine hills sur-

rounding Danzig - the important cultural, academic, economic and tourist seaside center. Currently AMBER is a one of the most developed and modern breweries among the small and medium Polish enterprises. The original recipe, which has been passed on from generation to generation, seems to be a key

Beers of the year 2008 voted best by consumers in the annual contest by browar.biz

A special recipe for the

traditional taste factor for the unique quality of AMBER’s products and their growing popularity on the national and world market. The “secret” recipe combined with the usage of natural ingredients and the traditional manner of brewing, results in several well-known, distinguishing themselves beer brands. Company’s production potential, which is estimated at 250 thousand hectoliters per year, enables a full and diligent control over the pro-

Food & Beverage Industry > Amber Księga1.indb 31

duction process. Furthermore, it gives a possibility for creating inimitable products. From the cooperative and logistic side, the company directly collaborates with the most valued distributors located over the whole region and in the biggest Polish cities. Since 2001, AMBER is also a shareholder in Presto – one of the most influential distributive companies of beer and beverage in north Poland. The whole process of distribution is strongly and directly supported by regional sales managers and commercial representatives, responsible for the development on the market, commercial contacts and promotional operations. In the qualitative terms, the brewery fulfills all International norms and standards required. It is in a possession of HACCP an ISO certificates. Owing to that, AMBER’s products are present on the European and American market as well.

How come AMBER’s beers are so exceptional? The merit lays in the individual approach towards each and every produced kind. Each comes into being separately, from the beginning, thus from the brewing, to the end, thus to the bot-

Brewery of the year 2008

Manufacturing-Journal 29 2009-10-06 21:45:58

tling process. What is more, the whole process is based on a traditional brewing method, which guarantees that company’s products will always distinguish themselves by their unique taste. This is also a factor which differentiates AMBER from the mass production companies, which apply so called “high gravity” method. It basically rests on the production of the very high essence substance, which is being thin down with water and carbon dioxide, during the process of bottling. However, the traditional method of brewing alone, it is not enough. AMBER’s success is directly combined with the special philosophy of brewing, with “Reinheitsgebot” – the Bavarian Beer Purity Law -, and with the usage of only natural and the best quality ingredients. There is no place for artificial improvements, preservatives, or some equivalents beneficial

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from the economic point of view. In the original text of the German Law from XV centaury, the only ingredients that could be used in the production of beer were water, barley, and hops. Currently, since 1993 “Reinheitsgebot” is no longer part of German law: it has been replaced by the Provisional German Beer Law, which allows constituent components prohibited in the “Reinheitsgebot”, such as wheat malt and cane sugar, but which no longer allows unmalted barley. Till today, these are the rules respected by the AMBER Company. It won’t be a betray if we write some more about those special ingredients, which determine the unique beer taste, and their origins. The main substance, post-glacial water characterized by crystalline purity and freshness, comes from company’s private intakes placed among the moraine hills. The yeast, cul-

Food & Beverage Industry > Amber 2009-10-06 21:46:01

tured in AMBER’s own propagation station, derives from the low fermentation of the Munich strain initiated at the oldest beer university - Weihenstephan Institute. Aromatic hops, presenting a specific bitter taste, ripen on the famous cultivation in the Lublin region, and barley itself grows on the company’s own corn-growing. However, the company still admits that without a real passion and professional skills of its brewers, it would not have been on this high stage of development here and now.

How AMBER keeps up appearance

Company’s marketing and advertising strategy is reflected by its promotional motto – From Pomerania naturally. It directly concerns a place of origin, which is a Polish region representing the richest brewery traditions in a country.

ABMER continues this almost legendary mission with dignity and devotion.

Company’s representatives claim that each AMBER’s brand is treated differently and exceptional. That is the reason why each is promoted in a different way, to underline various types of consumption of particular beer kinds, and the specific impressions that it creates. From the very beginning of its activity, AMBER has been dynamically conducting campaigns promoting and propagating the region itself and some local traditions concerning brewery. The company is a member of The Tourist Society Kaszuby, the biggest tourist organization in the Kaszuby region. Moreover, AMBER plays an important role in the Good Brand Pomeranian Club, which gathers the best food producers from the environs, promoting themselves under the common logo “Food from Pomerania”. Although, these more or less commercial activities seem to be just sufficient, the company does not rest on laurels. The brewery is an initiator and the general organizer of the biggest annual Pomeranian festive event - Koźlaki Bielkowskie AMBER BEER & FOOD FESTIVAL. This special event is being coordinated under the patronage of the international organization Slow Food. Each year, thereabout middle of September, visitors, tourist and enthusiasts are having great fun and a possibility of tasting some regional specialties, owing to AMBER’s initiative.

se unique brands and tastes that AMBER has to offer, we should definitely present a quick review. Brewery’s main assortment is a proposition of 9 main kinds of beer: Piwo Żywe (lager, based on the completely natural essence, the only Polish beer recommended by the International move Slow Food), Koźlak (Bock, the best Polish Beer 2006 and 2007), Złote Lwy (literally “Golden Lions” in English), Amber Classic (light beer), Red Mocny, Hanza, Gryf, Harde and Grand. The quality of those products is being appreciated not only by the consumers, but also by the professionals.

Even though AMBER brewery has been operating for relatively short period of time, it had been awarded far more than once. The titles and prizes that AMBER had collected constitute a material for a second article, so we will limit ourselves, just to mention the most important ones. In 2004 the company achieved a recommendation from the Slow Food International organization for beer Piwo Żywe. So far, it is the only such distinction in whole Poland. The year after, in 2005, Koźlak Amber and Piwo Żywe obtained two official signs of Ministry of Agriculture – “Try Fine Food”. Most importantly, though, since 2006 each year AMBER’s beers have been prizewinners in the plebiscite organized by website www.browar.biz. Such response is a best proof, that brewery has a great impact on consumer’s tastes and choices. For AMBER the satisfaction of its clients and receivers is indeed a best reward that the company can ever get.

FACT BOX FULL NAME: Browar AMBER PRESIDENT: Andrzej Przybyło OPERATIONS: Food & Beverage ESTABLISHED: 1994

www.browar-amber.pl

Brands and awards

Finally, after writing so much about the-

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Manufacturing-Journal 31 2009-10-06 21:46:03

INNOVATIVE SOLUTIONS

A

round the world, ground engineering is crucial to the success of major civil engineering schemes such as urban regeneration, infrastructure renewal and energy production. It is also an important factor in whether a project is delivered on time and to budget. Whatever the size of the project, and wherever it is, Keller has the experience and technology to provide an innovative, robust and cost effective solution.

Keller is a leading international ground engineering specialist. The company is renowned for providing innovative and cost effective solutions to ground engineering problems and refurbishment projects. Keller has unrivalled coverage in Europe, North America , Asia and Australia where its services are used in infrastructure, building, civil engineering and structural renovation contracts.

What is more, Keller has successfully developed ground engineering techniques that are now widely accepted in the construction industry. Today, it is the number one player in the United States and Australia. It has also a strong profile in many emerging markets and leading po-

32 Manufacturing-Journal Księga1.indb 34

sition in established European markets.

Keller in Poland

The company entered the Polish market in 1994. Since the time it managed to successfully implement almost one thousand projects. The headquarter of the enterprise is located in Ożarów Mazowiecki, near Warsaw. Local offices can be found in Gdynia, Kraków, Poznań and Wrocław. The locations are responsible for covering projects executed on the territory of Poland, although in Gdynia there is a main design office, where most advanced project are design. Obviously, from the number of projects the company worked on in Poland, the most sentimental ones remain the ones executed at the very beginnings of the business activity – underpinning at the medieval St. John’s church in Gdańsk, works at the Nysa dam or at the water-power station in Dychowo. – The most crucial moment for us was undoubtedly the connection of our design activity with performance.

It turned out to be a bull’s eye. We were the first company which offered such a comprehensive solution on the Polish

Construction Industry > Keller Polska 2009-10-06 21:46:05

market. The customers needed this kind of support. Their interest in our services propelled our activity – says Mr. Tomasz Michalski, the General Director of the company. He adds that the interest of the customers would not come if it had not been for the innovative solutions that Keller could always boast. The spectrum of the technology used in execution of the projects is incessantly extended. – No longer than three years ago we invested in new technology solutions. Owing to that, what we deliver to our customer, is complete geotechnics.

The customers value that – claims the Director. Another important factor turned out to be current financial controlling. It enabled observation of the financial figures and allowed to undertake rational strategic decisions. The ventures of the company have been perceived in a number of various competitions and contests. One of them is Gazele Biznesu 2003,2004 and 2007 (Business Gazelles 2003,2004 and 2007). The acknowledgement came for a Polish newspaper, Puls Biznesu, for dynamic development and growth figures.The company received also the title of Tytan in 2007. Last but not least, Keller Group is a laureate in Ground Engineering Awards 2009 in the category UK Project over £1 M. The project concerned strengthening the railway subsoil on the London-Norwich route with the DSM-dry technology.

because Keller works with them to find the best and most cost-effective solution from an informed engineering and construction viewpoint. Although Keller is a global player, it has a strong local presence in all its markets. Due to that, the company can respond quickly to the customers’ needs and changes in its marketplace. Wherever Keller works and whatever the size of the project, the enterprise brings strong contracting relationships, good logistics, specialist technologies as well as equipment, experience and excellent risk and safety management. In fact, the professionalism of the company caused that it is described as “the hidden giant” – not just for the obvious reason that most of its work is buried in the ground, but also because it recognises its inherent strength and capabilities. – The customers value what we do because the solutions offered to them are “tailor-made”. From the wide spectrum of available technologies we offer them the one which suits their requirements the most. We believe in the strength of being one step ahead of our competitors – informs Mr. Michalski. The image that the company would like to have among its clients is of an innovative company able to handle even the most difficult problems with the most technologically advanced solutions and tools. Because of that Keller has been always open for any initiatives, no matter what size or industry the customer would represent. The list of the companies it cooperated with includes not only general executors and large investors but also small, local firms.

All of that have a chance to participate in special seminars organized by Keller every so often and to learn about the novelties in the geotechnics industry.

The future lies in the people

One of the strengths of the company is expertise and in-depth industry knowledge of its people. Keller attracts quality people who are motivated by the culture of empowerment, excellent job support, good reward as well as recognition and opportunities for career growth.

The engineers employed at Keller appreciate continued investment in research and development and active encouragement of technology transfer between international branches of the company. This means new techniques can be introduced into geographic markets in the knowledge that support is available elsewhere in the Group from engineers experienced in those techniques. – We do not have any particular HR strategy. However, we are not afraid of investing into our people. We always find funds for various trainings and we give the employees a free hand: lots of autonomy and independence. We are more than sure that only self-reliance can evoke entrepreneurship needed for the success of both employees as well as the company – explains the Director. The attitude is reflected in the turnover figures. The employees value the trust that the company puts in their everyday activities. There are people in the company who has been working for it since the beginning, so it is 14 years.

The belief in the personnel is actually so large that the personnel is viewed as a strategic potential of the enterprise.

Solid and responsible

Next to the employees that the company cooperates with, lots of attention is paid to the local community and the social surrounding of Keller. The company recognises that its responsibilities

Why customers turn to Keller

The clients of Keller trust the company

Construction Industry > Keller Polska Księga1.indb 35

Manufacturing-Journal 33 2009-10-06 21:46:06

terials are increasing, the company decided that managing the environmental policy will be integrated with reducing operational costs and increasing efficiency. Due to that the company decided to focus on environmental management actions in four key areas: reducing site waste and noise, reducing the use of site fuel and company car and van fuel, reducing operational energy consumption, reducing paper usage and increasing recycling. In order to familiarize the employees with the environmental goals and techniques of implementing them in everyday work, diverse Keller branches establish working groups in order to share ideas and best practice and to develop further, more detailed guidelines which will help to put the theory into practice.

ting building codes, specifications and guidelines, as well as making presentations at seminars, teaching short courses and researching new construction methods. However, not just the knowledge and know-how are exchanged. In case a particular tool or device is needed in the process of the works, it can be brought to the site from another unit of the company, no matter in which country or continent. All that makes Keller Polska an obvious choice in a number of projects undertaken throughout Poland.

What is more, they are becoming more and more prestigious. The company is for example involved in the construction works of the Baltic Arena and the National Stadium erected for the EURO 2012.

Most probably, the projects will bring further recognition to Keller Polska and innovation it is so much familiar with.

Local company with extend beyond financial results and related matters. Effective management of social and environmental risk is important to corporate reputation and profitability. The company tries to ensure that appropriate policies and systems are implemented in order to identify, monitor and manage the social, environmental, ethical as well as health and safety risks which are material to the company’s business and which influence the environment in which it operates. The Keller Group does have a “one size fits all” approach to corporate social responsibility (CSR) issue. There is a common site of ethical values which is predominant throughout the business practices all around the world. Each company within the Group is responsible for ensuring that it meets local statutory requirements as a minimum and is encouraged to reflect best practice within the Group.The company identifies four main areas where its business impacts on others and where it recognises its responsibilities to the society. These are: workplace and people, marketplace and relationships with industry colleagues, community relations as well as protecting the environment.

global possibilities

Without doubt, the most crucial characteristics of Keller is that it operates locally, but the international background it possesses allows to widen its perspective to a global level. What the customers get from Keller is not just the knowledge and experience of the engineers who are involved in the projects. Throughout the execution of the works, the employees can communicate regularly with other employees within the Keller Group. Next to that, all companies in the Group undertake a wide range of technical trainings, which make the employees up to date with the latest developments in the industry. Many of Keller’s senior managers take a leading role in the geotechnical construction industry’s professional associations and activities around the world. They are involved in wri-

FACT BOX FULL NAME: Keller Polska DIRECTOR: Tomasz Michalski OPERATIONS: Construction Industry ESTABLISHED: 1994 EMPLOYEES: 300 REVENUE: 59 663 k Euros (2008)

www.keller.com.pl

Environmentally friendly

Environmental management is in fact an essential part of Keller’s approach to good business management, particularly as the enterprise’s construction-related activities can have direct environmental impacts. As the costs of waste disposal, energy and construction ma-

34 Manufacturing-Journal Księga1.indb 36

Construction Industry > Keller Polska 2009-10-06 21:46:08

FULL NAME: Stalfa Sp. z o.o.

PRESIDENT: Zygmunt Butrym OPERATIONS: Steel and Aluminium Construction Industry ESTABLISHED: 1995 EMPLOYEES: 220 REVENUE: 20 mln EURO

www.stalfa.pl

S

talfa, a Poland-based certified manufacturer of steel and aluminium products, is one of the top-notch companies of this type in Europe. With its cutting edge machines and highly qualified staff members, the firm has a considerable advantage over competitors and is prepared to accept even the most demanding challenges. The quality of Stalfa products has been appreciated many times by business partners that take the lead on the global markets. For this reason it seems thought-provoking to get to know how the enterprise found its way to the top rungs of the industry.

2004 and ISO 9001: 2000) that Stalfa implemented, brought the business a well-established market position and success. The company’s mission is to deliver top-of-the-range products and meet the customer’s requirements. This kind of policy is geared towards boosting customer satisfaction and winning customer confidence in the long run. Before this customer-friendly policy could be implemented, however, Stalfa had to co-ordinate and harmonize a number of various factors, including the high quality of anticorrosive coating, competitive prices and promptness of delivery.

When balanced appropriately, they help

the firm maintain the leadership among professional metal suppliers. As a reliable manufacturer, Stalfa provides a wide array of blueprints for excellence in aluminium and steel solutions. Thus, in dayto-day business it follows a set of useful principles. The manufacturing process is, first and foremost, organized to ensure the high quality, easy access to products and a prompt execution and delivery. The costs of manufacture are also very important. At each stage the company makes an attempt to reduce the costs unless it is detrimental to the quality. What is more, it tries to keep one step ahead of competitors as regards

NEARING EXCELLENCE IN STEEL AND ALUMINIUM CONSTRUCTIONS

FACT BOX

Build your position

Established in 1995, Stalfa quickly earned itself the reputation as an unrivalled supplier of steel and aluminium constructions among customers from Europe and the United States. A crucial event, as the enterprise admits, was the decision on purchasing a bankrupt factory. The acquired premises were a stepping-stone towards a launch of production and assembly of aluminium products. From incipient stages of the activity, the company has offered high quality, reliable goods. Functionality and safety of the products are in the foreground as well. These elements, when combined with a professional staff and quality management systems (ISO 14001:

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Manufacturing-Journal 35 2009-10-06 21:46:09

satisfying customers’ needs. It is part of employees’ regular employment to improve their skills and abilities. The managing personnel, on the other hand, is expected to revamp quality management systems by managing and supervising processes provided by the efficient performance of the system. Employees are the firm’s strategic potential.

Had it not been for them, as the company admits, the success and development would not have been possible. Currently the company employs about 220 people who are normally rewarded for their performance. This sort of motivation system is applied to all staff members, who are granted bonuses, financial and non-cash rewards upon fulfillment of clear-cut goals. Pursuing career is possible thanks to a special system that enables all employees to take part in many professional training courses and seminars. The enterprise gives each of them the possibility to improve skills and abilities, gain new knowledge, know the latest technology and techniques. The motivation system is also inextricably bound to career development. Experienced employees with an extensive knowledge and abilities are offered an excellent promotion.

Other ways of motivating employees are largely various group initiatives such as picnics, trips, excursions, tickets for the cinema, theatre or swimming pool.

Offer what they need

Stalfa has an attractive and customized offer which includes safety railings, systems of fencing for industrial premises, balcony balustrades, staircase railings and other items needed to complete building projects. All products are manufactured following very detailed customer’s recommendations and requirements. Since the company’s strategy means also a continuous development, Stalfa remains open to the manufacture of other products than those described below. One group of products is telecommunications masts and towers of different heights that are manufactured in co-operation with Valmont Polska, the renowned manufacturer of masts and poles. These are manufactured chiefly for such recipients as well-known telecommunications companies, e.g. Ericsson, Centertel, GSM and Hutchison. Safety railings are an indispensable element in building various types of stairs, balconies and ramps for the disabled persons. Stalfa provides a wide range of tailor-made functional and aesthetical-

36 Manufacturing-Journal Księga1.indb 38

Construction Industry > Stalfa 2009-10-06 21:46:10

ly-pleasing railings for the construction industry. Gas cylinder pallets and barrels stands are another type of products offered by the enterprise. They are suitable for both forklift handling and transport with hook hoist equipment. Additionally, they can be fitted with belts to secure cylinders from moving. The pallets are tailor-made to exact specifications and, further, hot galvanized or painted. Pallets and containers are heavy-duty and easy to use, which makes transport and storage safe and economical. They are designed for transport of any building accessories as well as for warehouse management. Locker cupboards are an interesting element of the business offer. Being made of steel and designed to comply with the customer’s requirements, they are ideal for fitting out school and workplace locker rooms. In recent years the manufacturing profile of Stalfa has been expanded to include aluminium constructions which ensure a particularly long lifetime. With its qualified welding team, the company has all it takes to provide the best quality of products made on the basis of received documentation. The enterprise has particularly great experience in the manufacture of steps, ladders and platforms, but given its production capabilities, experienced workers and state-of-the-art machines, it will be happy to accept any challenge. The most popular of all products described above are towers and masts.

They are in demand nowadays and, as Stalfa believes, this group of products appears to be the most promising one.

Go green!

implemented with a view to saving energy and recycling secondary materials.

Float around the market

Just to reiterate, the enterprise works in the construction industry as an individual steel products contractor. The goods provided by Stalfa are used mainly in construction, telecommunications, power engineering and road building.

The predictions do not indicate that the scope of areas is going to change in the near future. Instead the firm is planning to maintain and continue the present manufacturing profile along with expanding the current offer to more aluminium products. At the same time the contractor is well aware of the economic hazards of running a company. As many European companies, it has been affected by the recent economic slowdown and volatile situation on the European markets. However, if the company is to overcome the difficult period, it must reduce all possible effects of the risk and, preferably, search for positive values that can be found in the present circumstances. For example, many years of experience have shown that Stalfa is competitive both on the Polish and overseas markets. Besides the prices, the quality and promptness are equally important. At present the firm is in the process of enhancing the manufacturing, so the products are highly likely to become even more competitive and maintain the leading position among suppliers.

Stalfa conducts business mainly on the European markets. Currently, it co-operates with companies from Germany,

Austria, Denmark and Luxemburg. EastEuropean markets are seen as an area for a further expansion of the business.

Let it be spotted

Being proud of what they have is probably a good encapsulation of the company’s achievements. The strong and well-established market position speak for themselves, so it would be difficult to overlook accomplishments of such a flourishing business. The Polish Steel Constructions Chamber honoured Stalfa with the certificate Producer of Steel Constructions, which confirms the reliability and high quality of steel constructions. The company can also boast the prestigious award Business Gazelle that it was awarded with four times in a row (2005, 2006, 2007, 2008). The prize is given to companies which develop rapidly and fill the top ranks of their industries in terms of the quality of products, reliability, transparency of financial records etc. Moreover, in 2008 Stalfa won the first prize, in the region of the Mazowieckie province, in the competition Pillar of the Polish Economy. Apart from the above distinctions, the enterprise implemented the quality management system ISO 9001:2001 and the environmental protection system ISO 14001:2005 concerning the manufacture of light-weight steel constructions.

Thanks to SLV licence it is permitted to weld both steel and aluminium components. These are considered to be pivotal to Stalfa because they specify the ways and methods that impact on the quality.

The company is not indifferent to green issues too. It has adopted an environmentally-friendly policy. The manufacturing process of metal constructions and other components is safe both to human health and the environment. Since the company implemented the system, it has been able to control the environmental pollutants and follow legal regulations concerning the protection of the environment. Training courses are organized to raise employees’ awareness of dangers and risks of pollution as well as to bring their attention to the need and methods of the environmental protection. Stalfa attaches great significance to the implementation of new technologies. They help to reduce air, liquid and gaseous waste produced in the process of manufacturing, as well as the noise level. Other technological solutions are

Construction Industry > Stalfa Księga1.indb 39

Manufacturing-Journal 37 2009-10-06 21:46:13

AR TI CL ES

IT’S HARD TO STAY ON THE ROOF WITHOUT FALLING – RELIABILITY OF TERMATEX PRODUCTS

FACT BOX

FULL NAME: Przedsiębiorstwo Usług Specjalistycznych TERMATEX Sp. z o.o.

www.termatex.pl

S

tanding on a pointed roof and playing the fiddle at the same time is a risky situation. A fiddler on the roof has to keep balance to survive. Stability and professionalism are the key to establish a position on the business market. Fictional fiddler on the roof lends itself to a metaphor of balance that thriving firms can keep.

TERMATEX is a company which definitely possesses these values.

Written by: Karolina Burkiewicz TERMATEX is a notable representative of the market leaders of roof coverings and wall claddings in Poland. It is an ideal business partner for the investors and the general contractor for industrial and retail rooms. The company employs around 300 people, among which 40 employees are engineer and technical staff, and the remaining rest is the bluecollar workers. They work at the Board Office in Ostojów, the Steel Construction Manufacturing Company and Sales Department in Starachowice, seven Marketing and Retail offices located all around Poland and also on building sites.

Cross Mountains, which are one of the oldest mountain ranges in Europe. At the beginning, the target was the production of basalt-claddings and provision of all building works. The turning point in the development of the TERMATEX was establishing a close cooperation in 1991 with the German company AW ANDERNACH GMBH & CO. KG, which has its registered office in Bonn and specializes in the production of bituminous insulating-seal materials. The cooperative interaction provided access to upto-date materials and advanced technologies, which were not widely used in Poland then, and initiated new ways for development of the Polish firm. It began

to be oriented at the production of roof coverings for large-surface retail and industrial complexes. The range of materials used included, at first, thermoweldable tar paper, and later also, PVC (polyvinyl chloride) foil and EPDM (ethylene propylene diene Monomer) rubber. Apart from roof coverings, over the course of time, TERMATEX broadened the scope of services for manufacturing wall-claddings, using the latest technologies available in the market. Up to now, the company sold around 10 million m2 of roof coverings and 1 million m2 of exterior elevation, which is a commendable achievement. The decision to open an independent Steel Construc-

Breakthrough year

TERMATEX is a specialist services company operating in the Polish market since 1987. It was one of the first firms set up in the region of Świętokrzyskie Voivodeship, located in south-central Poland and surrounded by the Holy

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Construction Industry > Termatex 2009-10-06 21:46:14

tion Manufacturing Company in 2008, for TERMATEX’s own purposes was another stepping stone in the progressive growth of the firm. It was conditioned on the appropriate possibilities that the company possesses, i. e. technical issues and staff. The new factory is mutually advantageous for both, TERMATEX and its customers. It enables the company to produce new items according to the market demand, and also broadens and provides access to all services at close hand. The prospective customers of TERMATEX enjoy the wide range of its services and convenient location. The Steel Construction Manufacturing Company was co-financed by the European Union within the European Regional Development Fund (ERDF). The fund is allocated only to the companies which passed the factual assessment of their projects with flying colours. Because of this achievement, TERMATEX can be boldly summarised as a company signifying professionalism and high business potential.

Keeping on schedule

TERMATEX earned a good name for providing high quality of its wide range of services and using high class and innovative products. Top priority of the company is meeting the deadline at all costs, as delays in orders disrupt the schedule of the customers. The second important concern for the firm is flexibility. TERMATEX does it utmost to match the customers’ requirements.

Finishing on schedule and versatility combined with longstanding experience, qualified management and constant number of labourers through the years won the trust of the companies cooperating with TERMATEX and enticed them to use its services again.

Maintaining advantage

The company is built around people.

People are, first and foremost, the greatest asset of TERMATEX. Their appropriate knowledge, qualifications and experience can be identified with the firm’s strategy. Strong and stable financial position enabling carrying out high priced orders and modern machine parts saving the time and increasing safety are just another strength of the company.

Last, but not least, are the materials suppliers who have cooperated with TERMATEX for years, and also trusted and supported the company. It is worth mentioning that this year, the firm, as one of the few in the roofing trade, has

implemented and used the integrated ERP (Enterprise Resource Planning), which is designed for the construction industry and which helps in organisation of the company’s activities, optimization of business processes and effective control over financial resources.

Outlining success strategies

How to determine ‘success’? It is a question frequently asked during the interviews for a job. According to the employees of TERMATEX, success can be defined as a goal for a definite period of time. In the past, it was being a leader in the production of roof coverings and wall claddings for large-surface buildings in Poland. It was accompanied by earning respect as a reliable company employing professional workers performing their tasks on time and winning the trust of their customers. All these factors contributed to retaining the position of one of the top employers in the Świętokrzyskie region and keeping the increase of employment stable. The current target for TERMATEX is development remaining within the scope of services provided by the company, e. g. production and assembly of steel construction, so that the firm would become known as an independent manufacturer of steel products in a few years’ time. The rapid growth of the company is also connected with entering the foreign markets and opening up for new technologies.

How to seduce young staff?

The employees with thorough knowledge and accumulated experience, who have been attached to TERMATEX for years, are the hard core of the company. However, new applicants for vacant posts should not be discouraged and intimidated by their older colleagues.

Young workers without experience have the opportunity of undergoing a training course and then training period, while people with high qualifications are immediately delegated to responsible duties, as was the case with new personnel of Steel Construction Manufacturing Company. TERMATEX invests in workers by improving their qualifications, namely, organizing language, workplace safety and computer courses, training courses organized by the Office of Technical Inspection and also training courses on the use of company’s products.

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A name to conjure with

TERMATEX has already got positive associations with a large specialist services company producing roof coverings and wall claddings and using the latest technologies available on market. Still, the firm is pinning its hopes on developing the Steel Construction Manufacturing Company, which would enable it to produce and sell whole items to its customers in one place. Therefore, one day, TERMATEX may also be known for manufacture and assembly of steel constructions.

International cooperation and awards

Cooperation with foreign countries is not restricted only to buying the products from Austrian and German building materials suppliers. The bridges of international teamwork extend to training courses on products and their application techniques. TERMATEX was also commissioned to perform works, directly by foreign countries.

The company can boast of the following awards and distinctions: • • •

Business Gazelle 2005 granted by the business daily e-paper Puls Biznesu (The Rhythm of Business) Time Machines in the ranking of Gazeta Prawna (Law Journal) conducted in 2007 The Pillars of the Polish Economy in the ranking of Puls Biznesu.

Not just a bowl of cherries

TERMATEX does not violate ecological laws and has ethical approach towards environment protection, which manifests itself in the industrial waste management. In addition, the company uses proecological technologies, e. g. solar batteries heating the water for welfare purposes in the Steel Construction Manufacturing Company and oat and cherry stones burner for heating the firm’s office block. Ecological solutions cut the heating costs and do not disturb the balance of nature.

flares up, there are attempts to satisfy either side of the argument. TERMATEX’s strategy is not to go to extremes in solving the problems, but moderate the opinions, which is not an easy task in the business environment.

How far is poland from western europe?

TERMATEX is aware that Polish companies have to make up for the lost time in the sphere of organization, technology and technological solutions, as compared to the countries of Western Europe. Yet, the present time creates favourable conditions for a step forward and buoyant economy.

Working out a compromise

The company’s workers cannot remember any customer who they would be ashamed to offer their services to again. It does not mean that the firm’s profile is without a blemish and that it aspires to be the ideal guiding light.

However, whenever a heated dispute

40 Manufacturing-Journal Księga1.indb 42

Construction Industry > Termatex 2009-10-06 21:46:17

FACT BOX FULL NAME: LG ELECTRONICS MŁAWA Ltd. PRESIDENT: Jang Hyeu Lee OPERATIONS: Electronics Industry ESTABLISHED: 1999 EMPLOYEES: 1666

LEADER IN DIGITAL TECHNOLOGY

LG Electronics Mława Ltd. the biggest electronics establishment in Poland

REVENUE: 4 bln PLN

pl.lge.com View on production facilities

tronics industry, while at the same time increasing its market share in the home appliance, air-conditioning and business solutions sectors.

A golden decade

Mr. Daniel Kortlan Director of Corporate Affairs LG Electronics Mława Ltd.

L

Mr. Jang Hyeu Lee CEO LG Electronics Mława Ltd.

G Electronics’ innovative technologies, unique products, and cutting-edge designs are an investment in the future. The company is a global leader and technology innovator in consumer electronics, mobile communications and home appliances. LG is one of the world’s leading producers of PDP and LCD TVs, audio and video products, mobile handsets, air conditioners and washing machines.

LG Electronics Mława’s efforts continue to enhance the global presence of the LG brand and to maximize profitable growth. In particular, LG Electronics will focus on achieving sustainable growth in the mobile communications and home entertainment sectors to strengthen its leadership in the Elec-

LG Electronics Mława (LGEMA) is a Poland-based subsidiary of LG Electronics. It was established in 1999 as a result of a takeover of CURTIS Electronics.

The new company acquired premises, equipment and a staff of 250 people.

Initially, LGEMA manufactured conventional CRT TV sets but owing to numerous investments made in 2000 and 2001 the company managed to reorganize the manufacture and launched the production of higher class TVs, i.e. Flat TVs, LCD TVs and Plasma TVs as well as 32” TVs. In those years the production rate stabilized, reaching the level of approximately 500 thousand products.The years 2003 and 2004 were a significant formative period during which LGEMA established Centre for Production of Components and built new manufacturing halls and warehouses. It allowed the company to start the manufacture of LCD and PDP television receivers. The new products were designed to comply with environmentally-friendly technologies by eliminating or reducing emissions of harmful substances. In order to achieve this object the company implemented a series of manifold practices.

For example, it developed a technical know-how for processing of plastic materials (application of nitrogen-assisted

Electronics Industry > LG Electronics Mława Księga1.indb 43

injection) and painting methods (use of water-soluble paints). The Centre for Digital Products was also established and the production rate of high tech TVs soared. The policy was continued in 2004 when LGEMA, among other things, completed the expansion of the manufacturing and logistics facilities and brought new innovative products to the market. In 2005 the firm reached a significant milestone when an investment agreement between Polish government and LGEMA was inked. It was a watershed in the company’s history which enabled it to develop even more rapidly. The LG concern decided to invest the amount of USD 110 million in the expansion of the Mława manufacturing plant. An extra land was allotted to build new shop floors and a research centre.

The enlarged factory was to provide extra 2150 new job positions until year 2010. What is more, LGEMA also joined a special economic zone, thus being given tax relief until 2017. The creation of a ‘co-operative companies cluster’ made it possible to employ hundreds of new workers. The investment was an

The Voivod Jacek Kozłowski presents the management with a special diploma on the occasion of the 10th Anniversary

Manufacturing-Journal 41 2009-10-06 21:46:20

LCD LH9000

outcome of a consistent development strategy aiming at the implementation of innovative digital solutions. In 2005 a committee consisting of representatives of embassies and trade chambers granted LG Electronics Mława the title of Investor of the Year 2005. At the same time the Korean investment, with its annual production rate of 1.2 million products, was hailed as the best company in the Mazowsze region. With the onset of 2006 the business saw the opening of a new MA2 manufacturing plant featuring large logistics facilities. A new shop floor was constructed with dizzying speed and was made operant after five months. In August the first plasma module left the assembly line. Those events had obviously impacted on the firm’s employment, which reached almost 2000 people, and the manufacturing capacity that crossed the threshold of 3 million products. Soon after that the construction of yet another manufacturing plant started. The MA3 plant was completed in 2007, commencing the period of stabilization. A Supply Chain Management was implemented and “On Time Delivery” system was revamped. The changes were a considerable enhancement of logistics, which contributed to the increase in the production reaching 4.3 millions TVs and monitors in 2007. The following year was dubbed the year of innovation. In 2008 LGEMA reached the best Key Performance Indicator (KPI) among overseas subsidiaries of LG located outside Korea. The indicator measured the annual

42 Manufacturing-Journal Księga1.indb 44

increase in production, efficiency, economy as well as the quality of products.

Recent tendencies

Currently, LGMA is in the process of implementing four crucial strategies simultaneously: cash transfer maximization (implemented via a level, pull-based production control system, a shortened time frame for the final product delivery and a reduction in supplies), competitiveness in all areas (including innovation in regular costs, increase in the efficiency and productivity, competitive suppliers and providing them with the idea of elimination of losses), innova-

tion in Supply Chain Management (concerning chiefly the increase in direct “on time deliveries” and the increased role of local suppliers) and enhanced organization skills and abilities (including replacement of Korean staff members with Polish managers). As the company admits, it is planning to maintain the same production rate as in 2008, yet Mr. Jang Hyeu Lee, CEO of LG Electronics Mława, claims that it is possible to reach the manufacturing level of 6 million TV receivers and monitors in 2009. Such result would be another milestone in the firm’s annals that would confirm its strong position even in the midst of the global economic crisis. Today many global markets fly through economic turbulence resulting in unstable currencies, growing unemployment, plummeting demand and consumption and lower prices of electronic equipment. Even if Poland manages to steer out of the crisis or weather the storm, it may prove hard for LGEMA to maintain the present position on the European markets. However, the company’s management board seems to have a good strategy. As Corporate Director, Mr. Daniel Kortlan, reveals, LGEMA plumped for innovation and the policy paid off. The business is nowadays a top-of-the-range provider of LG products. A similar status quo is also maintained by local officials: “The LG logo is associated with high quality products. The electronic industry, represented by the concern worldwide, is part of high tech industries which are indicative of ultra-modernity and a very dynamic development, also in research and innovation,” says Mr. Włodzimierz

Electronics Industry > LG Electronics Mława 2009-10-06 21:46:22

tinuity at plant’s floor level, dropped significantly – from 10 pct to 1 pct,” says Mr. Lee. “We had to recruit top talents from the outside to fill senior positions, but it proved successful. High level of professionalism of Polish managers at LG Electronics Mława and their willingness to take on new tasks assures me that the future of our company is safe,” he adds.

The LCD production line

Wojnarowski, Starost of the Mława District. At present LGEMA has a strong and well-established position on the market.

From incipient stages of its activity, the company has gone a long way to reach the top rungs of the Electronics industry.

Each year was paved with a new dose of energy and creativity. Recent production rates provide an awe-inspiring productivity growth figures in the past years.

Asked about the reasons for such a big growth, Mr. Jang Hyeu Lee enumerated manifold factors: “we have launched new methods of assessing productivity in all aspects of our work. Every week we evaluate productivity of teams and recognize top performers (…) We have also changed the production system: previously, the assembly line was moved forward by a worker after completing a single operation (so called pull method), while now the line moves slowly (so called push method) and a worker can adjust his or her speed of work to the assembly line without wasting time on starting the assembly line after every single operation. When we introduced individual evaluation of employees, level of absenteeism, so important from con-

LCD LH 7 series

Treasure confined to locality

It goes without saying that LG Electronics Mława is widely respectable in business environment but the company also developed sound co-operative bonds with local authorities. The bilateral relations are flourishing. LGEMA improved the region’s employment rates significantly as well as it raised investors’ interest in the Mława region, e.g. Dong Yang Electronics. LGEMA co-operates also with the local self-government and the State School of Higher Vocational Education (PWSZ) in Ciechanów. Last year the company helped the local college launch a BSc programme in electronics and telecommunication in Mława. PWSZ was presented with monitors, plasma TVs and equipment for use in practical classes and laboratory work. At the moment the course in electronics and telecommunication is studied by about 80 students and, in the forthcoming academic year, another programme is going to be launched – IT studies. The chancellor of PWSZ, Prof. Andrzej Kolasa, PhD, MSc, reveals that “higher level education in electronics, telecommunication and IT would not be possible without help and commitment of LG Electronics.” And last but not least, the business is also engaged in charity. In 2008, for instance, LGEMA made a considerable amount of donations to educational and cultural institutions and different associations and social organizations. It seems that such admirable actions add lustre to the company’s success – both global and local.

LCD LU 4 series

LCD LH 8 series

LCD LU 5 series

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Manufacturing-Journal 43 2009-10-06 21:46:29

Firma”PICARO” Tadeusz Piórkowski ul. Olsztyńska 2, 12-130 Pasym Tel/Fax: +48 089 533 1265 e-mail: picaro.tartak@wp.pl

P - precision I - innovative C - consummation A - ambition R - reliability O - onus

What makes STYROMAX outstanding?

•

• • • • • • • • •

High quality of products: ceilings coffered, battens, rose-windows, styrofoam boards, styrofoam boxes, styrofoam corners, styrofoam fillers, styrofoam packaging for household appliances and audio / video devices, styrofoam shapes, injection moulding manufacturing, e.g. car safety seats, bike helmets, styrofoam shapes obtained in the process of thermal cutting, heat insulation, angle brackets, U-profiles, decorative cornices, products for vegetable gardening and horticulture such as sowing boxes, multi-cell plant trays, granulated products; Being one of few manufacturers of expanded polypropylene products (EPP) in Poland; Short lead time; 14 years of experience (since 1995); Own tool-room – adaptation and modernization of injection methods; Use of state-of-the-art machines of renowned brands: Kurtz, Erlenbach, Heitz, Teubert; Own technical and repair service; Quick production of packaging – within 24 hours after preparation of mould; Own transportation depot; Mobility – location in central Poland.

P.P.H.U. „STYROMAX” 99-420 Łyszkowice Kolonia 4A tel./fax: +48 46 838 88 70 mob.: +48 512 476 785 e-mail: biuro@styromax.com.pl www.styromax.com.pl

44 Manufacturing-Journal Księga1.indb 46

. . . . . . .

Company „PICARO” – it high quality production of wood palette, platforms and roof construction.

We own: • palettes type EURO ( EUROpalettes) of dimension 800 x 1200 • single-use palettes • non-standard palettes according to orders • palletboxes • working platform • industrial palettes 100 x 1200

Most modern injection park in Poland - with gas system and injection clumping force from 100 to 1800 tons The plant has a 16 000 m2 area; TÜV Saarland e.v. Certificate of Management Quality ISO9001 and Certificate of Environment Protection System ISO14001; Casing production for LCD TV with measurements from 17” to 60”, cars seats for children and automotiv parts; Long-term collaboration with companies such as: LG Electronics, TOSHIBA, Humax, Ramatti, EKAplast, Rosti; 4 modern painting lines including one with 3 robots of ABB company; Store house of high storage of surface 4800 m2 with capability of reloading 256 palettes on day.

EKA-Production Sp. z o.o.

www.ekaproduction.pl

Electronics Industry > LG Electronics Mława 2009-10-06 21:46:31

Via our magazine BusinessPL you can: / Razem z BusinessPL: • ontact influential people in business; / docieraj do wysoko postawionych osób • be found easily and available; / daj się odnaleźć, bądź dostępny • take part in important events; / bierz udział w ważnych wydarzeniach • read experts’ advice; / czytaj rady ekspertów • raise your point, tell about your company; / zabierz głos, opowiedz o swojej firmie • adopt the right strategy and direction; / obieraj dobrą strategię i kierunek działań • build your image; / buduj wizerunek • get to know the language of business; / poznaj z nami język biznesu • talk in a “business” manner; / rozmawiaj „biznesowo” • access business information from the inside; / pozwól sobie na informacje o biznesie „od kuchni” • get to know the well-planned, strategic and effective BUSINESS; / poznaj przemyślany, strategiczny, efektywny BIZNES

Find out that “business is business” and be part of it!

Odkryj, że „business is business” i bądź w nim razem z nami

Z - MEDIA Długa Street 48/38 31-146 Cracow Poland info@businesspl.com www.businesspl.com

tel 1: 0048 12 4337115 tel 2: 0048 12 4337065 tel 3: 0048 12 4337066 fax: 0048 12 4337116

Manufacturing-Journal 45 Księga1.indb 47

2009-10-06 21:46:35

46 Manufacturing-Journal KsiÄ&#x2122;ga1.indb 48

2009-10-06 21:46:37

FULL NAME: Proplex Group PRESIDENT: Aleksandr Golikov OPERATIONS: production and sales of PVC profile ESTABLISHED: 1999 EMPLOYEES: 500

www.proplex.ru

P

roplex Group is one of the biggest producers of PVC profile in Russia. The company was founded in 1999 and in 2000 the PVC profile manufacturing plant was opened in Podolsk, Russia to meet the growing demand for PVC profile of high quality.

This year Proplex group has its 10th anniversary, which is quite a serious period for business in Russia. It definitely shows that company has overcome the problems associated with early stage of development and is now a mature company in its prime. For this 10year period Proplex has made a great progress in both production and commercial spheres. Now it is among the five largest extruding companies (10% of the market share) in Russia due to regular extension of its production capacities, successful development of warehouse and sales network, quick and innovative approach to dealing with consumer needs and high brand recognition in Russia. Plans for future are still no less ambitious and include market share increase, reaching to new clients, creating new products. Company’s great value is its highly-qualified personnel and open trusting relations with its numerous partners.

windows with width from 46 to 127 mm.

These are Proplex-Tender (3-chamber), Proplex-Premium (5-chamber), ProplexLux (wide, 127 mm frame), ProplexBalcon (2-chamber), Proplex-Comfort (4-chamber), Proplex-Optima (3-chamber door system) and Proplex-Optima (3-chamber window system). PROPLEX™ plastic profiles systems are all compatible and in this way, it is possible to produce window and door profiles of any form and size taking into consideration customers’ individual needs. In addition Proplex plant produces PVC

AUSTRIAN TECHNOLOGY APPLIED IN RUSSIA

FACT BOX

window inside and outside sills as well as window reveals. The range of accessories for doors and windows offered by the company is also quite wide - more than 50 items. A group of companies Proplex is also an official distributor of accessories produced by Roto (Germany) and an exclusive distributor of Kale (Turkey) accessories. So, the company can supply all range of accessories for doors and windows from PVC-profile.

To meet customer demands the basic PVC profiles colors are white and brown, but one can choose from the wide

Proplex Product Portfolio

Currently the Proplex plant produces seven PVC profile systems for doors and

Plastics Industry > Proplex Księga1.indb 49

Manufacturing-Journal 47 2009-10-06 21:46:38

range of colours and be sure that colour coating is maximally weather-proof and will not change for a long time.

PROPLEX™ Products - Perfect Quality

The Austrian technology of PVC profile system used in the production process has been specially adjusted to Russian climatic conditions. The system meets all heat insulation requirements in Russia.

Quality of all Proplex products is controlled at 21 points of production process.

The quality control system includes the control of the production process itself — initial thorough inspection of raw materials, control on different production stages as well as final product control. According to accomplished tests Proplex profile systems in many aspects

even exceed the established requirements. So, the system has even been recommended by Russian Health Ministry for glazing in medical organizations, including maternity houses, hospitals as well as at schools. Proplex profiles can also be used in all climatic zones of Russia including the Far North regions.

The window consisting of a triple pane unit and profile system is constructed in the way that it provides maximum heat and noise insulation. In 2007 after a series of additional tests Proplex PVC profile service life has been extended

by Russian standardization organization Rosstandart from 40 to 60 years!

It is worth mentioning that Proplex is the only Russian company that meets the requirements of European environmental program Concern for Tomorrow.

PROPLEX™ profile windows are ecologically safe, they underwent state testing and received Certificate of Conformity, Hygienic certificate and Fire Safety Certificate. Profile quality is marked by the Gold quality award “Russian trademark”.

ping PVC composition to extrusion lines.

The project was realized together with the world leader in the branch - German company Reimelt. Such system is quite a phenomenon among Russian PVC producers. Both Russian and German specialists have worked to „tune” it and it was worth it — this technology helps keep the unique mixture recipe invented by an Austrian company Chemson the same, and it perfectly guarantees high quality of the product. Each profile type has its own optimal technological conditions, so the profiles are made on extruders with different characteristics.

Extruding machines are supplied by renown companies such as Krauss Maffei, A+G extrusion technology GmbH, Technoplast. All machines are designed, produced and adjusted by specialists from Austria and Germany. They also train personnel to work with the machines.

The production process is equipped with a closed loop water circulation, refining and cooling systems. All extrusion lines have cooling tanks with vortex refrigeration system. All technological wastes are then recycled by grinding in crushing machines and used as additive

Production and Technology Facilities

For sure one of Proplex success „ingredient” from the very beginning until now has been its production facilities and state-of-the-art technology. The Austrian extrusion technologies, being one of the best in the world, were adapted and applied in Russia. In 2000 the plant had only 2 extrusion lines, by the year 2007 there were 30! In 2007 the third workshop with 18 extrusion lines was opened. The company also has fully automated system of preparing and ship-

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Plastics Industry > Proplex 2009-10-06 21:46:39

to raw materials in the production of window sills and some of Proplex profiles. There is a separate lamination unit located in specially constructed building which allows to keep the working environment highly clean for extra quality „gluing” of laminate to profiles. The plant is also equipped with all necessary machines for servicing of extrusion lines.

In 2004 a new polishing machine was installed for finishing and renovation of the equipment. Repair, adjusting and renovation works are performed by the highly-qualified specialists who were trained in Austria. Proplex plant has its own state-of-the-art quality control laboratory with Austrian equipment.

Every hour a sample from each extrusion line is taken for testing. The profile is tested in low temperature, for impact resistance and finally corner weld resistance is checked to provide 100% correspondence to the requirements of GOST standards. The whole production and quality control processes are directed at one purpose — manufacturing of high quality European profile in the required quantity, whereas the quality always remains the greatest priority.

Good Distribution and

Reliable Partners — Good Environment for Success

Proplex company is characterized by perfectly tuned distribution chain

based mainly on two components — open and mutually effective relations with partners as well as well-developed warehouse network around the whole country. Currently the company has 19 regional affiliates and 3 dealer warehouses. The number of Proplex partners producing and selling plastic windows made of PROPLEX™ profile is more than 200. In November 2007 Proplex company has implemented special certification program for its partners.

This was a logical step as nowadays the name of PROPLEX™ is associated not with the PVC profile itself but with final products produced of it. So, to protect company’s good reputation Proplex group has to not only take care about supplies of profiles to window manufacturers around Russia, but also strive to be responsible before end-users.

The certification program involves fullscale audit of manufacturing process and sales offices of Proplex partners to check if Proplex requirements to technological process, personnel, customer service and complaint processing are observed.

Since 2008 Proplex company has implemented the Program aimed at assisting its partners in tender participation.

Proplex greatest treasure

For sure all mentioned above would not be a reality but for the flexible, openminded and enthusiastic personnel, both on management and production levels. Each employee is important for the company, so the group actively invests into staff qualification improvement by organizing conferences, workshops, seminars. Some specialists have been trained by Austrian and German professionals. Moreover, in Proplex group friendly atmosphere which rules from the first days of its foundation is highly encouraged and all the time developed.

If one has to describe Proplex group in a few words an appropriate way to do it may be: a team of professionals working to apply modern Austrian technology in Russia to meet clients’ needs on the fly!

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WE OFFER MORE FOR ALL WWW.MANUFACTURING-JOURNAL.NET

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Plastics Industry > Proplex 2009-10-06 21:46:42

Diebox and Effex-die

G

ruber Extrusion is changing the world of plastics profile extrusion radically with its Efficient Extrusion Die (Effex-die). “Finding the solution to one of the greatest problems in extrusion - stabilizing process reliability - was the basic consideration behind our development of the Gruber Effex Tooling”, CEOs Richard Füsslberger and Peter Gattinger said. Gruber Extrusion presented the system to the public for the first time in “Manufacturing Journal” to mark the 10th birthday of their client the Proplex Group. Innovation, competence and customer benefit are the common denominator: and it is these goals that have made the toolmaker ideas-smithy Gruber Extrusion of Pettenbach/Upper Austria to one of the world’s leaders in plastics profile extrusion. Füsslberger and Gattinger offered their congratulations and wishes for sustained success to the Proplex Group in the name of the entire Gruber Extrusion team.

die design allows pressure reduction and thus a significant energy saving.

The combination of the Effex-die with the Mixing ring and Mixing star in the Gruber melt mixer plus the standard die housing for Gruber Effex Tooling creates the optimal pressure conditions and assures perfect melt distribution. Separate parts of the system are patented or have patents pending.

The new system has been tested on different machines using the broadest range of raw materials in countless test runs. A one year practical test series in the USA confirmed the results. The homogenous melt brings significantly higher productivity than ever before slight differences in the PVC batches are balanced out by this while the tooling

WORLD PREMIERE FOR THE EFFEX-DIE

FACT BOX Technology: Gruber-Effex-Tooling Innovation: by Gruber Extrusion, Austria Operations: tooling and machinery for profiles in PVC, plastics and compounds plus turn-key-solutions Established: 1993 www.grubergroup.com application on various extruder types is made possible with no additional alignment work. “Put quite plainly this means more profit for the producers”, Richard Füsslberger said and added: “It is only very rarely that an investment in a new tooling system has brought such a fast pay-off.”

“Technology by innovation” is the Gruber Extrusion creed and common denominator for its high-powered activities in a succinct three word message.

The high-end tooling producer Gruber Extrusion is a global leader as a provider for plastics profile extrusion projects.

Gruber Extrusion is a Proplex Group supplier through its subsidiary a+g extrusion technology. Gruber Extrusion wishes Proplex a very happy birthday.

What advantages does the Effex-die

open up for the profile extruder? Production is maximized, rejects slashed down to a minimum. Extruder, material and temperature fluctuations are perfectly balanced. Flexibility increases as a result. The use of standard die housing that has proved its total reliability in many thousands of applications, assures compatibility with previous Gruber tooling systems. The special

Mixing star

Plastics Industry > Gruber Extrusion Księga1.indb 53

Mixing ring

Manufacturing-Journal 51 2009-10-06 21:46:43

R

ussian Railways is a strategic player in the Russian economy in terms of its financial leverage and social importance. At the same time, the Company has long been a vital link between East, West, North and South Eurasia. With an ambitious strategy of reform that is still under way, Russian Railways is now aiming to win new positions on the global transport market.

Russian Railways is entirely state-owned and has a monopoly on passenger and cargo transportation within Russia. The Company carries nearly 1.3 billion passengers and1.3 billion tonnes of freight annually, accounting for over 3.6% of Russia’s GDP and handling around 80% of all transportation in the country.

Russian Railways has an unshakable position on the logistics market and is one of the biggest transport companies in the world, with a network of 85,500 km of track across Russia’s 11 time zones, second only to the USA.

A vital role in economy

Russian Railways links East, West, North and South Eurasia

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The Company’s vital strategic role in Russia is explained by the country’s northern geographical location, its huge territorial extent and vast natural resources, many of which are in remote, harsh and sparsely populated regions of Siberia and the Russian Far East badly served by roads and far removed from the main population centres in European Russia.

Railways are therefore often the only available means of transport for countless passengers and bulk commodities.

Russia’s highly developed railway system is therefore vital to the country’s economic and social life and will continue to dominate transport for the foreseeable future, playing a vital role in virtually every segment of the economy. The rail network connects 85 of Russia’s 89 regions, provides services to most major cities and has a direct impact on growth, industrial development and regional integration. Russian Railways is a 100% state-owned rail monopoly with 987 enterprises and 165 subsidiaries. And with 1.3 million employees, it is the biggest employer in the country and one of the world’s leading freight carriers.

Transport and Logistics Industry > Russian Railways 2009-10-06 21:46:45

A little history

The history of Russia’s railways dates back to the Russian Empire in the early nineteenth century, when the first line was built to link the imperial capital St. Petersburg with Moscow. But it was under Pavel Melnikov, Russia’s first Minister of Communications, that the real development of Russia’s railway system began. Melnikov, a talented engineer and scientist, trained the experts who later built the railways in European Russia and beyond and made service on the railways highly prestigious. In the twentieth century, Russia’s railways continued their dynamic development and during the Soviet period, total track length increased from 115,000 km to more than 145,000 km. Major projects included a second Trans-Siberian line, the Baikal-Amur Main Line (BAM), which runs between Ust-Kut on the Lena River and Komsomolsk-on-the-Amur on the Pacific coast in Russia’s Far East. Peak traffic volume in the Soviet Union was reached in 1988, when the railway system transported 4,116 million tonnes of freight and 4,395.9 million passengers.

On the collapse of the Soviet Union, however, the old railway network was broken up into national systems based on newly independent Soviet republics.

This period saw the Russian economy in deep trouble, with a precipitous drop in production and an end to state support for the rail industry. As a result, funds were lacking to repair rolling stock, track and stations, let alone to carry out any

modernisation. The inevitable result was a rapidly aging and obsolescent infrastructure. It became obvious that in order to provide the range and quality of rail services Russia required, the rail sector would have to undergo thoroughgoing reform and modernisation, and in 2003, a vast structural reform programme was set in motion. On 18 September 2003, Russian Government Decree No. 585 established the Russian Railways Public Corporation, in which the state held 100% of the shares. As the Company’s sole owner, the Russian Federation delegates shareholder control to the government. The Ministry of Railways retains control of the regulation and government policy of railway transport, while Russian Railways manages the Company’s financial operations.

The reform programme

The reform programme was divided into three stages lasting up to and beyond 2010 and focused on updating production and the technical side, renewing track and rolling stock, achieving greater efficiency and increasing revenues, competitiveness and the motivation of railway personnel. Further important aims include the elimination of cross-subsidies and, in the medium-term future, partial privatisation. This process remains on track and Russian Railways’ finances are in great shape. The Company’s net income in 2007 based on International Financial Reporting Standards (IFRS) was EUR 4.1

billion, making it one of Russia’s most profitable companies, while assets as of 31/12/2008 were worth EUR 82 billion.

The Company fully executes its financial obligations to the State and has the highest investment ratings among Russian companies, with a reputation as a reliable partner on the financial markets.

The Company has wide-ranging and clearly defined plans for the future. By 2030, Russian Railways will spend more than 13 trillion roubles on acquiring new rolling stock and lay down over20,000 km of new railway lines to ensure transport to and from industrial zones and newly developed mineral deposits.

Russian Railways and the Winter Olympics

In 2014, Russia will host its first ever Winter Olympics, which will be held at the Black Sea resort of Sochi. Preparations are already in full swing for the Games, and Russian Railway is making a major contribution to ensure that Sochi will be ready to cope with the large numbers of visitors expected. We are building a special railway link to connect the Olympic Park, the airport and the sporting venues at Krasnaya Polyana. The Company is also modernising stations for people with disabilities. The line should come into operation in the fourth quarter of 2011 and be able to carry 64,000 people a day in each direction. Four pairs of trains will operate every hour at 15 minute intervals during busy periods.

In 2008, about 150 million roubles were spent on this project, which entails the construction of more than 2.7 km of single-line track, two 500 m long tunnels, about 2.8 km of electric cable, 800 m of overpasses and around 1,000 m of support walls. Russian Railways is also considering improving access to Sochi by establishing a high-speed link between Moscow and Adler with trains capable of 200 km/h. As a result, travel time between the two will take just 15.5 hours.

Russian Railways

- proud of its latest projects

One of the Company’s top priorities is to develop high-speed trains and approval has been given for projects on 18 routes with high passenger volumes. As a result,

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a pilot project between Moscow and St. Petersburg is underway and high-speed passenger services will be introduced between major cities such as St. Petersburg, Moscow, Krasnodar, Samara and Novosibirsk. These particular cities are not only major Russian hubs in economic terms, but also important tourist centres. A contract to supply the first Russian high-speed trains was agreed in 2006 with the German company Siemens AG. Four trains will be supplied for use on the Moscow- St. Petersburg route and four for the Moscow-Nizhniy Novgorod run. These trains are capable of speeds of up to 250 km/h, so that by mid-2009, travel time from Moscow to St. Petersburg will be cut to 3 hours 45 minutes, 45 minutes less than previously. According to Vladimir Yakunin, the President of Russian Railways, the fares will be lower than flights on the same route. Reducing the journey time is very important, especially for business passengers, which Russian Railways expects to be largest group to take advantage of the new fast connections. High-speed services between St. Petersburg and Helsinki is another of The Company’s important projects. Introducing these new trains will reduce travel time between the two cities to 3-3.5 hours, at least two hours less than the 5.5 hours required at the moment. Providing high-speed trains, in line with modern European requirements of comfort and security, will be a rapid technological advance for Russian rail sector. The high-speed programme is due to be completed by 2020. Key areas in the Company’s international activity include the development of closer partnerships with those coun-

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tries which, like Russia, use the 1520 mm broad-gauge track, namely Finland, the members of the CIS and the three Baltic countries of Estonia, Latvia and Lithuania. On 14 February 1992, the Council for Rail Transport of CIS States was established to ensure firm economic ties between the newly independent national rail systems. The Council works to maintain the unity of the railway lines and links through unitary provisions on the technical operation of railway lines and instructions on signalling and the movement of trains and shunting, as well as by agreeing operating principles. In addition, the Council organises the joint operation of freight wagons, containers and a common information space.

A socially responsible company

The human resources policy at Russian Railways is firmly based on long-term investment in staff. The Company makes substantial investments in its employees by supporting a large educational and training network specialising in the railway industry and providing scholarships to students. Through its charity and sponsorship programmes, Russian Railways also maintains its reputation as a most attractive and appealing place to work for all of its employees. Russian Railways makes every effort to reduce the impact of its operations on the environment. In recent years we have successfully reduced harmful emissions into the air, water and ground, even as production has increased. Russian Railways will also enable Russians to decrease CO2 emissions on a larger scale by attracting many passengers from air to rail.

FACT BOX FULL NAME: Russian Railways PRESIDENT: Vladimir Yakunin OPERATIONS: Transport and Infrastructure Services ESTABLISHED: 2003 EMPLOYEES: 1.2 MILLION REVENUE: EURO 32.8 BN (2007)

www.eng.rzd.ru

Transport and Logistics Industry > Russian Railways 2009-10-06 21:46:47

KEEPING YOUR FOOD IN A SAFE PLACE

FACT BOX FULL NAME: KREIS PACK Sp. z o.o.

OPERATIONS: Packaging Industry ESTABLISHED: 1993 EMPLOYEES: 200

www.kreispack.pl

K

reis Pack is a Polish manufacturer and provider of food containers. It has what it takes to be among the leading European companies offering various food packaging items. During sixteen years of activity it proved to be very competitive on the European markets by providing, at reasonable prices, top quality products that range from OPS containers and cutlery to PP containers, cups and trays. In order to better respond to customer’s demands Kreis Pack offer was broadened to include EPS containers and aluminium containers. The company also developed a robust business policy that takes into account the needs of all people connected with the Kreis Pack brand – customers, suppliers, workers, etc.

Building professional environment

At incipient stages of its activity the company has been quick to realize the commercial potential of plastic products. Founded in the early 1990s, Kreis Pack originally worked as a distributor of disposable tableware imported from Germany. However, it was not long before the business grew strong enough to move into the manufacturing sector, where it gained ground soon afterwards. Several momentous events are currently a reminder of the successful development of the business. Chronologically, the most important decisions were, for example, starting the production and opening an office in Niepruszewo, entering Eastern markets, opening a

Packaging Industry > Kreis Pack Księga1.indb 57

branch in Żyrardów, where the production of PP containers was launched, and introducing the company’s products to chain stores such as METRO (Makro) and SELGROS. Nowadays the products offered by Kreis Pack are available both in Poland and abroad. They are popular on the domestic market as well as on export markets. Such popularity would not be possible without the customerfriendly policy. Therefore, the enterprise attaches great significance to improvement and perfection of products. Being a good listener is essential, as it allows for recognizing the customers’ needs and responding to them as soon as they arise. Building customer confidence is a long-term process that cannot be achieved by merely providing decent quality products. It also requires profes-

Manufacturing-Journal 55 2009-10-06 21:46:51

sionalism in other areas. For example, excellent customer service is one of the underlying principles to take into account. Kreis Pack made improvements to delivery time; basic products are constantly available in warehouse stores and customer complaints are responded to as soon as possible. In addition to this, the company gives customers the possibility of designing their own special-purpose packaging patterns as well as imprints on selected products. And, more importantly, the producer believes that preferential treatment is totally unacceptable. Equal attention is given to all customers ranging from the biggest distributor to the smallest warehouse, though, as the company admits, loyal and regular customers are appreciated by being additionally assisted in developing their businesses. It goes without saying that every business has a goal.

That of Kreis Pack is simply to be the best in what they do. The company reveals

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that competition is huge but it is perceived as a motivating factor which spurs Kreis Pack into action.

Over fifty percent of the firm’s output is currently exported – mainly to Germany, to mother company KIV Kreis GmbH, which operates on the markets in Western Europe, and to East European markets. The company’s plans and hopes are now revolving around the expansion to the Balkan states.

run the risk of conviction. Kreis Pack containers are resilient products which are perfect for storing food and confectionery, e.g. salads, sweets, cakes, etc.

The packaging items are made from high quality materials and they show enhanced resistance to creases, as a result. They also come in different patterns and sizes, which makes them both more attractive and more practical. For instance, a container of the same diameter can have different depths. The present offer includes a variety of plastic packaging items which are manufactured with the use of thermoform and injection technologies. The core of the production focuses on OPS food containers and cutlery. The popularity of the enterprise is owed mainly to these products. The production of other items such as plates, cups, EPS containers, aluminium moulds, etc. is also very important. As regards the emerging areas

Focus on the product

of the business, the development of the plant in Żyrardów and the promotion of polyprophylene packaging take priority.

Products provided by Kreis Pack are, first and foremost, synonymous with high quality at an affordable price. The prices are by no means fixed at the expense of the quality. The company emphasizes that it strongly disagrees with those kinds of practices.

In fact the customer is the best judge, so any businesses attempting to save on the quality of their products immediately

Towards the greener globe

In the past couple of years a worldwide tendency has been, in broad terms, towards ecology. Containers made from a biodegradable material based on polylactic acid are becoming more and more popular. Bottles produced from this material decompose within 75-80 days.

Other solutions are, for example, ‘chinet’, which is, basically, a biodegradable packaging. Polish market is unfortunately sluggish, adjusting to these trends at a slow pace. This is because in Poland the most important factor is still the price. Modern and efficient eco-friendly policy is the reason why Kreis Pack does not lag behind Western states in terms of the adjustment to recent tendencies.

The blanking scrap from the production

Packaging Industry > Kreis Pack 2009-10-06 21:46:52

process is ground and used again for the production of cutlery. Two major implications arise from this method. Firstly, the company offers top quality cutlery, as it is obtained from raw material. Secondly, the amount of waste products is kept to the minimum, which adds luster to the firm’s environmental policy. The green-related efforts were appreciated, as in recognition of the policy the company received a certificate Zgodnie z rytmem natury (Friendly towards nature).

Kreis Pack, with its total staff of almost 200 people, belongs to medium-sized businesses. It is, therefore, of great significance for such enterprises to get involved in various non-professional activities with a view to developing a sense of membership in workers. The company tries to integrate employ-

and containers.

It seems that there are many things that Kreis Pack can take pride in and social activity is definitely one of them. In business environment it has been operating incessantly for over sixteen years on the market of packaging items. Such a long time of operation allowed for building a strong and well-established position and encouraged a sustainable growth of the business. As the company admits openly, it is proud of the fact that the Kreis Pack products are available

ees by organizing meetings and other events on regular basis, e.g. Christmas party. On the whole a family-friendly approach is advocated. It aims, among other things, to help expectant mothers in their handling of professional affairs. For this reason the HR department policy deserves full credit. Employees are also given Christmas presents and those who encounter some problems are offered financial support. In other areas the firm marked its presence as well. It regularly supports local community, which usually takes the form of non-cash support. A local kindergarten, foundation ‘Barka’ and participants of Lednica 2000, a meeting of Catholic youth on the Lednica fields which is organized by Fr Jan Góra, receive the Kreis Pack products on regular basis. What is more, the company also supports “Wielka Orkiestra Świętej Pomocy” (nationwide winter fundraising campaign organized by Jerzy Owsiak) by supplying it with tableware

in an international chain store Metro.

The purchase of the plant in Żyrardów is also considered to have been a good investment. There are a number of ways to check and verify the prosperity of a company. Perhaps the most reliable method is to take a peep at its achievements, especially those that have been appreciated by others. For this reason awards and certificates that a business received are vital, as they can serve as a sort of a warranty that attest to high quality, reliability, good economic per-

Let the sleeping pride awake

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formance. Kreis Pack can boast one of the most prestigious titles granted to business entities in Poland – Gazela Biznesu (Business Gazelle). The producer was honoured with the title four times in a row, i.e. in 2005, 2006, 2007 and 2008. The award is given to businesses which show a sustainable growth and development, yielding very good economic results at the same time. In 2007 Kreis Pack also received the title of Gepardy Biznesu (Business Cheetahs).

To sum up, the company achieved a series of successes that allowed for a dynamic development and sustainable growth of the Kreis Pack brand.

Today, the producer wishes all European companies a fruitful development.

Manufacturing-Journal 57 2009-10-06 21:46:54

DYNAMICS IN ALL ASPECTS A FLOFARM is a Polish company active in the pharmaceutical industry. It started its market activity as a pharmaceutical wholesaler.

Today, after twenty years of business operations, AFLOFARM boasts 5th position among Polish medicine manufacturers with respect to quantity and 8th position with respect to value.

The company manufactures over 160 products and employs around 500 people in three modern manufacturing plants located in Pabianice, Rzgów and Ksawerów, in central Poland. What is more, the enterprise is characterized by impressive development dynamics. The fact has been confirmed by many distinctions and awards.

Family run business

AFLOFARM started its activity in January 1989 in Pabianice as a family company run by Grażyna and Andrzej Furman under the name AFLOPA. The aim of the company was production of medicines, however at the beginning AFLOPA functioned as a professional financial advising company. One year after the establishment, in 1990, AFLOPA started wholesale activity and medicines trade. Within a year, the enterprise became a big pharmaceutical wholesaler with four branches scattered around the whole territory of Poland – in Pabianice, Wrocław, Radom and Bielsko-Biała. The year 1993 witnessed

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a very important decision. AFLOPA concentrated on the production of medicines, what was its purpose from the very beginning of business operations. At the beginning of the manufacturing activity, the enterprise started with simple galenical formulas. However, after gaining the first experience, observing the dynamically developing market and perceiving the variety of customers’ needs, AFLOPA took to production of composed medicines.

Years 1993-1997 were time of dynamic development of production activity. Within the time, the offer was extended up to 100 products. In 1997 the company took the decision to expand the medicines’ production and to quit the wholesale activity. - It was a turning point for our company, which propelled its development and strengthened the market position – says Mr. Jacek Furman, the President of ALFOFARM. In 2002 AFLOPA transformed into two independent companies: AFLOFARM Polish Pharmacy Ltd. and AFLOFARM Medicines Factory Ltd. Nowadays, two of the companies operate successfully on the pharmaceutical market. AFLOFARM manufactures products widely known among patients, pharmacists and doctors. It comes down to the fact that many of its preparations are leaders in their therapeutic class.

Pharmacy Industry > Aflofarm 2009-10-06 21:46:55

all requirements of valid law provisions.

What is more, they contribute to building consumers’ trust based on manufacturing of safe products consistent with prerequisites of quality criteria. Another proof of the top quality focus of AFLOFARM are results of successful audits conducted by the Main Pharmaceutical Inspectorate in 2006. After the completion of the whole procedure, AFLOFARM received Certificate of Good Manufacturing Practice.

Offer – marketing and research

Product strategy: quality and innovation

– What makes our products peculiar are their high quality and innovation – claims Mr. Furman. In fact, top quality of the products as well as their safety and efficiency are of great priority for companies operating on the pharmaceutical market or dealing with production of medicines, diet supplements and cosmetics. Taking into consideration the necessity to ensure high quality and to provide customers with safe and efficient products, AFLOFARM companies have implemented the following Quality Management Systems: PN-EN ISO 9001:2001, GMP and HACCP. The systems ensure constant supply of products meeting both the needs and expectations of the customers as well as

Without doubt, AFLOFARM’s advertisements and commercials have been seen or heard by almost every Pole. The company is second pharmaceutical advertiser in Poland. The colossal advertising activity is proved for example by the fact that the enterprise is the only company in Poland that promotes around 55 brands in an active way and successfully. For other Polish market players the figure does not exceed 6-7. – We base our marketing decisions on painstaking marketing studies.

Owing to that, we are able to get through to the customer – informs Mr. Furman.

The offer of AFLOFARM includes: • prescription medicines (Rx), sold to the customers once the prescription of a physician is shown, • over-the-counter drugs (OTC), available in every chemist’s shop and sold with no prescription requirement, e.g. vitamins, painkillers, syrups, etc., • diet supplements, enriching the every day diet and providing the organism with crucial substances and elements, • cosmetics.

At the current moment, the product offer of ALFOFARM includes around 160 products. What is more, the figure is getting larger and larger as new products regularly appear on the market. Research is namely of crucial value for the company – R&D department is almost a mission to AFLOFARM. What confirms the importance of the area, are high investments in this field. In 2007-2008 assigned over 16 million PLN for R&D. The enterprise incessantly looks for new solutions, technologies and ways of curing in order to unreservedly fulfill the expectations of patients, doctors and pharmacists. What turns out to be helpful in this respect, is close cooperation with scientists and experts from various scientific institutions, e.g.: Medical University of Lodz, Medical Academy of Warsaw, Medical Academy of Gdansk, Polish Academy of Science. Furthermore, at AFLOFARM it is

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believed that everything is possible. Due to that, the company always looks for new possibilities and solutions as well as is not afraid of implementing new technologies. Thanks to this innovative attitude, it manages to introduce significant novelties onto the Polish market. An example of that may be Nosaller, a crucial solution in fighting the air borne allergy. The product received recommendation of the Polish Allergic Association and Innovative Product distinction in a competition Leader of New Technologies. It must be mentioned that AFLOFARM Medicines Factory Ltd. offers manufacturing service of medicines, diet supplements and cosmetics such as: tablets, coated, hard capsules and powders packed in sachets. The unit is also ready to manufacture medical products for clinic research according to owned license. On the other hand, AFLOFARM Polish Pharmacy Ltd. can start cooperation in manufacturing of medicines, diet supplements and cosmetics such as: liquids (syrups, suspensions, drops, spirits), ointments and lotions, creams and gels. At present, AFLOFARM is the biggest contractual manufacturer in Europe.

Personnel and customer focus

AFLOFARM takes care not only of the top quality of its products, but also attaches great significance to the relations with employees and cooperating companies. The Management of the enterprise is more than sure that success of the company depends on the success of its employees. At the current moment, around 500 employees work at AFLOFARM. The Human Resource is the main value of the enterprise – the achievements of the employees strongly influence the company’s position on the market. Investing in staff is the best investment for any pharmaceutical company as it is directly transferred into its competitiveness. Ventures that the company undertook in the recent years significantly increased its employment.

Next to the personnel focus, the enterprise does a lot to maintain good relations with its contracting parties and customers. – As far as B2B contacts are concerned, we would like to be associated with dynamic decision making and reliability. In case of customers purchasing our products, we want all of them to find something for themselves in our offer – says the President. In fact, in 2007 AFLOFARM Polish Pharmacy Ltd. received the title of Fair Play Company. It confirms that the enterprise builds its activity on transparent rules and reliably meets the obligations towards contracting parties and workers.

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The Management of AFLOFARM thinks that durable success can be achieved only through honest, loyal and partnership based relations. The company also tries to put the concept of CSR into practice.

It supports financially a basketball team, actively participates in diverse charity actions. As far as the local community is concerned, AFLOFARM established an association concentrated on the maintenance and protection of historic buildings.

Looking back and ahead

According to the President of the company, the greatest changes that have appeared on the pharmaceutical market within the last five years, are considerable price decrease as well as greater awareness of the customers. - The average price level is shrinking. Moreover, the price drain has been really quick and no one actually predicted it. The customers have also changed. The effects of marketing activity do not appear as soon as they did some time ago. The customers are much more aware as before – claims Mr. Furman. Due to that, the company looks for new markets and plans to expand its business activity outside of Poland. At present, some of the manufactures are exported, yet the figures are not significant.

Among the destination countries one can find, e.g.: Romania, Hungary, Turkey and Slovakia. Negotiations concerning new foreign markets are just taking place. If they turn out to be a success, new development tracks will appear for AFLOFARM. Without doubt, the dynamic company will take advantage of them to the full.

Pharmacy Industry > Aflofarm 2009-10-06 21:46:58

European standards and innovative technologies

S

ince beginnings in early nineties Zeller Plastik Poland has developed into one of the most important and innovative producers of plastic closures and packaging components in Poland. Through the continuous modernisation and specialisation of production plants, it has become a model of development of the highest quality. In a market which is becoming ever more global and competitive, only those companies which present modern concepts, can be effective and bring profits.

Important member of Global Closure Systems

The first plant of latter Zeller Plastik Poland, the limited liability company, belonged to Crown Plastics Poland company, which earlier was Carnaudmetalbox – Tworzywa Sztuczne. The name of the business was changed after Crown company had sold all manufacturing plants to Pai Partners group in October 2005. Zeller Plastik Poland, like Zeller Plastik Deutschland and Zeller Plastik Rus, belongs to Global Closure Systems which owns 30 factories in 16 different countries and employs about 3.500 workers. The manufacturing group produces various kinds of packages dedicated to food, pharmacy, cosmetics and household chemistry. Based in Wola Rębkowska, near-by Garwolin ( 55 km away from Warsaw), Zeller Plastik Poland produces plastic bottles, closures and

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packages made with IBM technology (jars, “roll-on” packages, mascara components). Zeller Plastik Poland produces standard and custom closures which are also manufactured by other sister companies – the ones that belong to international Global Closure Systems. The Polish company not only represents them in Poland, but also participates in contacts with all of these companies, including: Zeller Plastik Deutschland, UCP, Massmould and Astra. The annual capacity of the extrusion blown products amount to 170 million, for injection moulded closures a capacity is 800 million and for IBM products a capacity is 60 million (e. g. mascara, jars and “roll-on”).. More than 200 employees work in 4 shifts, seven days a week and 355 working days per year. As an important and developing member of Global Closure Systems Zeller Plastik Poland benefits from the resources of a widespread and growing network of companies manufacturing plastic closures and packaging. Among the customers they serve there are many international producers and world-famous brands such as Avon, Beiersdorf, Colgate, Henkel, L’Oréal, Procter & Gamble and Reckitt Benckiser. The company has the ISO 9001 certificate since 1999 .

From modest beginnings to effective business

The first plant of Zeller Plastik Poland was launched on 5 September 1994 in

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Garwolin 55 km from Warsaw and at that time it was called “Carnaudmetalbox – Tworzywa Sztuczne”, the limited liability company as a part of Mass Market Bottles Division. International brand Procter & Gamble was the first customer and since 1995 only bottles were produced with extrusion blown moulding. In 1996 the factory was bought by Crown, Cork Seal company and since November, the Injection Moulding Technology was started In 2000 the plant started to produce packages called “Marius” and in 2001 it broadened its offer by manufacturing mascara components which are used in cosmetic industry. At that time the company got “Złoty Medal” for a package called “Marius” on the Poznań International Fair Taropak 2001 and opened a new injection hall of 1300 m2. As a member

FACT BOX FULL NAME: Zeller Plastik Poland Sp. z o.o.

PRESIDENT: General Manager Member Of The Board - Jarosław (Jerry) Janowski OPERATIONS: Manufacturing of plastics closures, bottles and jars ESTABLISHED: 05/09/1994 EMPLOYEES: 210 REVENUE: 83 mln PLN

www.zellerplastik.pl

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of economic-consumer program called „Biała Lista” the company was confered the “Solidna Firma 2002” title. In 2005 the firm was favoured by getting on the list of “Gazele Biznesu 2004”, which is an exclusive trade ranking prepared by reputable and advisory Polish daily paper “Puls Biznesu”. At that time the company also opened a new injection hall of 700 m2 and soon in 2006 it finally changed its name to Zeller Plastik Poland

The Products

metic, household cleaning, foodstuff packages and pharmacy industries.

The plants produce different kinds of closures: with flap; “flip top” type; with in-built tap (also silicone one); dosing ones; multipart ones which require installation; with caulker inserts or inductively welded foil; safe ones such as CRC (Child Resistance Closure); with a shelter before the first use; bi-injection type; with decoration (using hot foil or screen print). On basis of many difficult and sophisticated methods the company also manufactures mascara components.

The whole process uses several technologies such as the injection moulding to produce the whole range of brushes; extrusion blowing (IBM) to manufacture bottles of different shapes; decoration, screen print or hot foiling; and half-automatic installment of all elements. All mascaras produced in a plant are based on reserved patterns and forms, so that the company can not use them on the free market without client’s knowledge.

The offer of the Polish firm also includes production of cosmetic jars with usage of two different kinds of technologies Zeller Plastik Poland specializes in. These are the injection (IM) and the injection blowing (IBM). The last group of products the company produces is „roll on” packages. They are manufactured according to special patterns preserved by client, so they can not be used in any other project. Furthermore, Zeller Plastik Poland offers producing packages and components of special use, formats and shape which differ from the standard one and require extraordinary approach in a stage of designing and planning. The best example of such activity is manufacturing a special package called „Marius” or a package used for air freshener

Zeller Plastik Poland produces the whole range of bottles using extrusion moulding technology. The shape and form of a bottle can vary according to the needs and requirements of an individual client and technology limits of the company.

Non-standard projects can be prepared in a graphic studio of Zeller Plastik Poland. Bottles can have decoration which is basically multi-colored screen print or wrapping foil film processed with “hot stamping” method. Zeller Plastik Poland offers the whole spectrum of plastic closures which are available in standard and custom format and shape • National transport/ Transport krajowy; and manufactured • International transport/ Transport międzynarodowy; in Polish plants • Year of company establishment - 1990/ Firma powstała w 1990 roku; as well as in the • Membership in ZMPD/ Członkowstwo w ZMPD other manufacturing sites based all over Europe. The FIRMA TRANSPORTOWA „TRANS-LEM” Mirosław Leszczyński Ul. Żwirowa 61 closures produced 05 – 300 Mińsk Mazowiecki by the Polish comTel./Fax. +48 025 758 68 72 pany and Global Mob. +48 0602 503 558 Closure Systems trans-lem@wp.pl are used in cos-

Packaging Industry > Zeller Plastik Poland 2009-10-06 21:47:00

FULL NAME: Intersilesia Mc Bride Polska Sp. z o.o.

PRESIDENT: Grzegorz Król OPERATIONS: Cosmetics Industry ESTABLISHED: 1990 EMPLOYEES: 377

www.intersilesia.com.pl

I

ntersilesia McBride is a Polandbased manufacturer of high-quality cosmetics and household chemical products. It supplies big chains of supermarkets and discounters as well as wholesalers both in Poland and abroad. During almost two decades of its activity, the company has earned a good reputation as a reliable business partner and manufacturer. To make a business offer more comprehensive and meet the customers’ expectations, it constantly tries to improve quality and widen a range of products.

origins date back to 1927 when Robert McBride created a business in Manchester supplying chemical processing products to Lancashire’s cotton industry.

Nearly two decades later the business was moved to Middleton, where the present registered office of McBride is located. At that time the first consumer product, i.e. bleach, was delivered overnight in glass bottles to local corner shops.

The 1960s commenced the period of rapid development during which the business gathered momentum. For example, in response to the growing demand,

the enterprise developed own system of blowing of plastic bottles. In 1975 it acquired Gretna Laboratory operating in Burnley and brought toiletries products to the market. One of the plants of McBride is still located in Burnley. Then, in 1986 Robert McBride became the first UK manufacturer of private label laundry liquids. McBride Ltd was established in 1994 and four years later the business acquired 85 percent of shares of Intersilesia Sp. z o.o., thus increasing its manufacturing capacity. Soon after, the opening of sales offices in Hungary and the

OUTSTANDING COSMETICS AND HOUSEHOLD CHEMICAL PRODUCTS

FACT BOX

Gathering momentum

The history of the business was shaped by growth of two companies. The first, established in 1990, Intersilesia, was an enterprise operating on the Polish market as a joint-venture with a German investor. In the early days of its activity, the enterprise was granted a licence to produce and distribute “Schmees Kosmetik Gmbh” products. Subsequently, following its acquisition by the British concern McBride in 1998, it widened the offer to include household chemical products as well as personal care products that were made available to the leading wholesalers in Europe under own-brand names and other minor brand names.

McBride’s history is an illustrative example of growth through innovation. Its

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Czech Republic followed the event. The company also saw a boost in sales in Romania and Ukraine. And eventually, Intersilesia McBride took over a chemical plant Schneider situated in Zabrze, south-western Poland, which resulted in greater production capacity of the Intersilesia plant. The culture of innovation and entrepreneurship that was evident at the incipient stages is still pervasive in all aspects of the company’s activities. McBride, initially just a local cottage industry, is currently a multinational business with an annual turnover of over £500m, operating out of 16 factories in six countries. Wojciech Mazurek, the managing director of Intersilesia McBride, reveals that the next stages of development will be conditioned by appropriate decisions concerning a range of products, business relations with international chains of stores, and predictions about market trends.

respond to them immediately. The company’s policy perfectly combines extensive experience with an advanced knowhow. It is aimed to satisfy the market demands by providing customers with top-quality products which are offered at competitive prices. In order to enhance this approach, Intersilesia McBride conducts research in laboratories as well as it draws upon experience of its daughter companies from Western Europe. Prioritizing customers is not part of the policy of Intersilesia McBride. Quite the contrary, every client is given equal treatment and every client is equally important. This policy applies to both wholesale companies and chains of supermarkets such as Tesco, Biedronka, Lidl, Metro, Carrefour, to name just those which are the main recipients of products. To customers the products of Intersilesia McBride should be, first and foremost, connotative of innovation and high quality at an affordable price. At present the business still grows and strengthens its position. It continuously widens the offer of its products and increases the production capacity. On the one hand, it is planning to further develop ‘private

label’ products, but, on the other hand, it is not going to neglect own brands.

As Mr Mazurek admits the company invests a lot in body care products and it also shows great interest in the CentralEastern European markets. With its experienced team of professionals, excellent location and production capabilities, the plant situated in Strzelce Opolskie is very important to the enterprise and it is likely to play a significant role in the company’s plans to strengthen its position as a provider of cosmetics and chemical products for the West European markets.

Recent trends

In the past five years the enterprise has turned from a local business into a big manufacturing plant which is part of a renowned international concern. Nowadays, it employs a total of over 350 staff and offers about 800 products which are manufactured not only in Poland, but also in the UK, Belgium, France and Luxemburg. The company sets itself clear-cut goals, which are implemented on regular basis, and moves towards achieving its object, i.e. to be the pre-eminent

Map the priorities

It is not a revelation that customers’ confidence is pivotal to the success of a business. Since it has an enormous influence on a brand, this phenomenon seems to be a prerequisite for the general prosperity on the market. In the case of Intersilesia McBride, the customer confidence is ensured chiefly by three factors to which the greatest significance is attached: quality, offer and price. In recent years the company has been also working in partnership with its customers in order to develop new products. This aspect of co-operation helps to better understand the customer’s needs and

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Cosmetics Industry > Intersilesia Mc Bride 2009-10-06 21:47:04

and most efficient supplier of top-of-therange household and personal care products to the leading retailers and brand owners. Many of the products manufactured by Intersilesia McBride are available on the European markets under various brand names. In general, export is on the increase. The number of products sold abroad each year grows very quickly and the enterprise expects this trend to continue. In recent years sales have regularly soared by several dozens of percentage points and there have also been such years that saw the number doubled. This trend was observed both on the neighbouring markets, e.g. in the Czech Republic and Hungary, and on the distant markets, e.g. in Kazakhstan.

Human factor

There are many things that Intersilesia McBride can be proud of, including the modern manufacturing plant, the well-established position on the market, a wide array of products or the customer trust etc. However, had it not been for people working with Intersilesia McBride, the development would not have

been possible. It is therefore ambitious and committed staff members that give the company the greatest satisfaction.

The human factor became particularly visible when the enterprise was being taken over by the international concern because the period of changes required a lot of effort from all staff members. On the other hand, as the company highly values its employees, it wants them to feel rewarded not only financially. It organizes trips and excursions for employees, barbecue parties and cultural events. For instance, recently the company arranged a fancy dress ball in the spirit of communist Poland. There were food cards, red gillyflowers, speeches of senior members of the communist party, and of course red ties. Those born a bit earlier chatted about their childhood in communist times, whereas those who were too young to experience those events in person listened to the stories and sampled the delights of the ball.

Nevertheless, everyone had a great time wearing a disguise. One could see headmen, ordinary workers, party comrades, communist youth, and even enemies of the communist regime – ‘Solidarity’ members or businessmen trading in money. By contrast, other events are organized on regular basis. Every year McBride Group arranges in Ieper, Belgium, a street run – half marathon for the distance of 22 kilometers. Five editions have taken place so far, each one gaining more and more popularity. Every site of McBride Group in Europe may have own representatives, so employees of Intersilesia McBride also take part in this event.

Cosmetics Industry > Intersilesia Mc Bride Księga1.indb 67

Awards and certificates

Intersilesia McBride was granted numerous prestigious certificates and awards for the quality of products, management and general prosperity of the business. The most important awards include: • •

• • • • • • • • • •

Certificate of quality management system (ISO 9001:2000) Certificate of environmental and occupational safety and health integrated management system PN-EN ISO 14001:2005, PN-N-18001:2004 The Best Product of Opole 2000 European Medal for Antibacterial YPLON range 2002 European Medal for AVEA range 2004 Fair Play Company 2004 Fair Play Company 2005 Investor of the Year for Opole Province 2005 Fair Play Company 2006 Bronze Statuette for Fair Play Company 2006 Gazelle of Business 2006 Gazelle of Business 2007

Manufacturing-Journal 65 2009-10-06 21:47:06

INNOVATIVE APPROACH TO PUBLIC TRANSPORT

FACT BOX FULL NAME: Minsk State Production Unitary Company „Belkommunmash” GENERAL DIRECTOR: Vladzimir Mikhailovitch Korol OPERATIONS: Manufacturer of public transit electric vehicles ESTABLISHED: 1973 EMPLOYEES: 1700 REVENUE: 120 mln/dollars

http://www.belcommunmash.by AKCM - 42003A „VITOVT”

B

elkommunmash is nowadays the biggest trolleybus producer in the world, the leading production General Director enterprise of Vladzimir Korol Belarus in manufacturing and repairing of electric transport. It is a dynamic company offering complex innovative and environmentally friendly solutions for public transport in modern cities.

of trolleybuses, 2 types of trams, fire and emergency vehicles as well as machines for public use. The enterprise is located on total area of 87,000 m2, whereas production facilities occupy the territory of 32,636 m2. Quantity of the basic technological equipment amounts to 642 units.

The Last Word in Trolleybus and Tram Construction

Since 2009 Belkommunmash has started mass production of new generation trolleybus 42003. The body of it is made of „eternal” composite materials. Progressive electronic solutions are imple-

Step by Step Development

Back in 1973, when the company was founded, it was called Minsk Repair Tram and Trolleybuses Plant (MRTTZ).

The company’s main activity was repair of public electric transport. For 25 years more than 6,500 trolleybuses and trams were repaired and in 1995 the production of the first generation of Belarussian trolleybuses was started. In 1996 the second generation of trolleybuses was released and soon after it in 2000 the first Belarussian tram was produced.

By the year 2007 Belkommunmash offered to the market the trolleybus of the fourth generation, where all flagship ideas of trolleybus construction were successfully applied. Now Belkommunmash production capacity is around 600 transport units per year. It offers 10 types

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tramcar model 84300M

Transport & Logistics Industry > Belkommunmash 2009-10-06 21:47:07

mented in every trolleybus system. This is a low-floor, two-door passenger trolleybus with AC traction electric motor and autonomous source of energy — condenser batteries. This trolleybus has perfectly modern design, spacious aisle, climate control system, big LCD-monitor on a driver board, ABS-system, floor level control system, automatic centralised grease system, built-in CAN technology, GPS navigation system and other highly advanced features. The main parts are supplied by manufacturers with world reputation, e.g., electric motors of Skoda, braking systems of Knorr Bremse, centralised grease system of Linkoln, driving gear of Skoda, Medcom and others.

Later on the basis of achievements in modern trolleybus construction the new low-floor tram 843 was designed. The interior of this tram is very comfortable and all parts are produced by the leading European manufacturers. The tram can reach speed up to 120 km/h. Passenger capacity is 206 (225) people, its lifespan is 35 years. All latest models of trams and trolleybuses are well adjusted for handicapped people. Construction of this tram is one of the brightest illustrations of company’s effective work, as the whole design and construction process has been finished within extremely short period of time — only one year!

trolleybus 333

Another important direction of Belkommunmash activity is production of fire and emergency vehicles. The first fire truck was produced in 1995 and in 1999 basing on experience with fire vehicles, emergency vehicle for Ministry of Emergency was made. In addition, in future Belkommunmash plans to develop a range of vehicles for complex servicing of roads, pavements, parks, lawns.

range of services to meet customers’ expectations. Company’s management was highly aware that nowadays it is not enough to be a producer of a good product in some country. So, to be competitive, an industrial enterprise has two ways: either to be a part of some other company’s supply chain or to create its own. Here, strong customer orientation suggested the way of further development for Belkommunmash. The transport facilities themselves take only 1/5 of all expenses during public transport investment projects. So, there should be someone to handle all complexity of such projects. And Belkommunmash did everything to become such a partner able to implement a complex turnkey investment project of trolleybus or speed tram traffic of its own production in any city and act as a main subcontractor during the project implementation. On further project stages the company is equipped to provide all required operation maintenance.

Comprehensive Approach

Proof of Success in Figures

Now this state-of-the-art experimental tram is already functioning on the streets of Minsk. As the company is in on-going search for new solutions and better results, currently the work is concentrated on creation of a middle-class bus (with capacity of up to 70 passengers) with hybrid drive. The combination of diesel and electrical engine (in future — hydrogen) will make the Belkommunmash transport even more economical and environmentally friendly.

Belkommunmash Vehicles

Belkommunmash is a unique enterprise, as it is the only one in the world producing both chassis and electric equipment of its own design for trolleybus and tram production. So, the company bears full responsibility for the quality of its products and provides all necessary maintenance.

What is extremely important is that Belkommunmash has not narrowed its activity to just designing, producing and selling of electric transport. Instead, the enterprise chose a way of offering full

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Currently demand for Belkommunmash production exceeds the supply twice — the factory produces 600 units per year, whereas customers are ready to buy more than 1000. Apart from all advantages mentioned above a good price-to-quality relation undoubtedly stimulates the sales. Belkommunmash does not produce trams or trolleybuses for storage, but still is able to make the order in a very short period of time with all customer’s desires in mind. Company’s main goal is to find individual

Manufacturing-Journal 67 2009-10-06 21:47:08

ing salon, a shoe repair workshop, a medical centre.

Target Markets

approach to each client and meet all the expectations. So, a consumer may get a tram or trolleybus with absolutely unique features, „tailored” specially for the given client. This kind of attitude made dynamic growth of the company possible. The production output is rising by around 30% each year. The profit received in 2008 as a result of trams, trolleybuses, vehicles sales and providing different services is 168,9% in comparison to the previous year. The company is highly profitable — 15% is the average profitability level in 2009. To keep the positive dynamics the company’s priorities for the nearest 5-10 years include such aspects as: effective implementation of advanced technologies, building of long-term relations, designing of new machines, lean production and cost reduction, gaining new markets and further strengthening of company’s positive image. The company provides employment for around 1700 people, 151 of them are managing staff. There are more than 1000 workers directly involved in production process. Therefore, Belkommunmash, being a responsible employer successfully helps solve social problems. For example, the company built four blocks of flats, a comfortable hostel, a health-improving camp for children, a rest camp, a laundry, a hairdress-

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For 36 years of its work Belkommunmash has won the reputation of a reliable and competitive partner.

During the last few years Belkommunmash mainly performed orders for public transport companies in Minsk and 8 other Belarussian cities.

However, in 2009 the company is performing orders mainly for foreign companies.

The orders come from Moscow, Saint-Petersburg, Smolensk, Saratov, Simferopol as well as from Latvia, Mongolia, Kazachstan, Serbia, Kyrgyzstan. The most attractive markets so far are the CIS and Baltic countries, as mainly public transport facilities there are reaching the end of its lifespan and require modernization. In addition, Belkommunmash is actively developing new potential markets - Switzerland, Italy, Poland, Finland and also Latin America. In 2008 export amounted to 21,0% in total sales volume. However, Belkommunmash is searching for new partners every day to extend the geography of its sales and promote ecological transport solutions.

Deserved Recognition

Belkommunmash achievements and high quality of products have been appreciated both internationally and domestically. All products meet international requirements and regulations of UN ECE. Belkommunmash was awarded by the Belarussian State Prize in the engineering sphere for designing and mass production of trolleybuses and trams. In 2000 Coordinating Committee of the International Program “Partnership for the sake of Progress” awarded Belkommunmash with the honorary prize “Crystal Nike” for high achievements in the production dynamics and sales. In 2006 trolleybus of 32102 model was awarded as the best product of the year in the Republic of Belarus. On a „Public transport 2009” branch exhibition in Moscow 42003A trolleybus has become a winner in prospective production competition „Green light” in a category „Rolling Stock” and is recommended for use by public transport enterprises.

Public Transport of Future?

In the end it is worth adding that electric transport is definitely a great solution for modern busy metropolitan streets.

This kind of transport is environmentally friendly and silent, therefore it almost does not contribute to air and noise pollution. Modern trolleybuses and trams are very economical and consume very little energy, as they allow to save up to 55% of energy in comparison to older models. So, replacement of one older electric transport unit by a new one allows to save up to 10 thousand dollars per year. Electric transport also helps solve the problem of traffic jams. So, there is a growing interest in the world towards electric transport and Belkommunmash encourages to protect the environment for future generations together!

Transport & Logistics Industry > Belkommunmash 2009-10-06 21:47:10

FULL NAME: BOLARUS S.A. PRESIDENT: Grzegorz Sygnarowicz OPERATIONS: HORECA ESTABLISHED: 1962 EMPLOYEES: 250 REVENUE: 12 000 000 EUR

www.bolarus.com.pl

B

OLARUS is a company noted for using recyclable cooling agents, producing high-quality and durable refrigeration facilities and providing friendly and qualified service.

Yet, its beginnings were not easy and the road to success was paved with stones of failure. It was long before the firm established its position on the domestic and foreign market.

History

BOLARUS S. A. (a joint-stock company) is a firm specialising in the production of the refrigeration systems for the trade and catering purposes. It is located in Bochnia, a town famous for its historic salt mine, around 40 kilometres away from Krakow. The origins of the factory go back to year 1962, when it provided only repair service of the refrigeration facilities ordered by the nationalised trade units. The change of the company’s target took place in 1965-1974 when a modern production factory was built. The production was around 20 000 pieces annually in 4 assortments. Today, the number of the items manufactured remains almost the same, but they are available in 150 assortments. Throughout the 70s and 80s, BOLARUS was a state-owned enterprise. There was no dog-eat-dog competition in the refrigeration systems industry, and therefore, the firm did not develop and improved its products. From 1992 onwards, the company underwent a long process of privatization completed in 2003, when it was bought by a private investor, wellexperienced in the refrigeration branch.

Denationalization of the corporation paid off as it triggered a series of positive alterations: dynamic development, clear decision-making process, modernization of production technology and products, and broadening of assortment.

HORECA Industry > Bolarus Księga1.indb 71

Customer trust

Earning customer trust is one of the main goals for BOLARUS. The company is identified by its clients with credibility of service, wide range of products, high quality, production flexibility and good organization of work. The consumers rely on and remain loyal to the trademark of BOLARUS, e. g., food producers, scientific institutes, blood donation centres, and even the Polish President’s Office, to name but a few. The products boast high durability. To give an example, the refrigeration systems produced in the 70s are still used in some retail outlets.

Nowadays, vintage commodities are in demand and it is not surprising that the customers place an order for them. There is an old refrigerator called “KRAKUS” manufactured in 1963, which still works excellently at the reception of BOLARUS quarters. It is an object of delight for the visitors, who would like to purchase the model RETRO for everyday use.

ECO-FRIENDLY AND INNOVATIVE REFRIGERATION MANUFACTURER

FACT BOX

The popularity of the products

BOLARUS has the key to achieve the popularity of the refrigeration equipment. The products are reliable, durable, easy to operate, financially attractive, modern and environmentally-friendly. The company established its good reputation by receiving positive recommendations from the customers, stable market situation, excellent custo-

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Maximizing the value of the

firm

The guiding principle of BOLARUS is not only the financial value of the firm, but the staff and their individual attitude towards the products they make. The management of the company increased the expenditure on in-service training, specialist courses and postgraduate studies to improve qualifications of the work force. Investment in the employees pays for itself and helps to increase the strategic potential of the industry.

International cooperation

mer service and post-guarantee repair service located in various areas of the country with all the spare parts available. The employees of the firm are eager to attend to customersâ&#x20AC;&#x2122; enquiries not only at the moment of buying a certain device, but also throughout the period of using the items they purchased.

International market constitutes 70% of share in the overall production of BOLARUS. The company works together with all European countries, but its devices can be also purchased in the Middle East, the Far East, North America and Africa. The firm is trusted by manufacturers influential in the world market, who commission the production of refrigeration facilities under the brands of their industries. The international cooperation of BOLARUS with foreign companies is based on selling the products and buying the raw materials abroad.

Production and service

Ecological policy

Environmental Management System

BOLARUS is a flexible company, responding quickly to the requirements of the customers and the market. Although it specializes in the production of the refrigeration systems, upright freezers and the refrigerator displayed cases, it also manufactures specialist items, which cannot be found in the catalogue, but can be ordered by the customers, e. g. devices designed for the ships or laboratory equipment.

Personnel policy

BOLARUS motivates the workers by ensuring employment stability, equal opportunities for the personnel and the production workers and atmosphere conducive to efficient work. Due to the recent outflow of a great number of technical specialists and professionals to foreign countries, BOLARUS had to replace them with young, but eager to work and learn, people, for whom it provides training and courses preparing them for the job. BOLARUS ensures first-rate working conditions for the new members of the staff. Currently, there are 250 people working in BOLARUS and

70 Manufacturing-Journal KsiÄ&#x2122;ga1.indb 72

each and every employee contributes to the success of the company. Nowadays, it is not enough to construct a valuable product. It is necessary to advertise it and improve it continually. Therefore, a well-organised staff is needed to reach customers and convince them of durability, reliability and energy efficiency of the equipment provided by BOLARUS.

HORECA Industry > Bolarus 2009-10-06 21:47:14

(EMS) following the ISO 14001 standard was implemented in the policy of BOLARUS. As a consequence, technologies and materials are introduced complying with the environmental needs and only biodegradable cooling agents are used. The usage of a natural cooling agent R-290 (propane) is a novelty on the market and makes BOLARUS one of the foremost producers of refrigeration systems. The recycling process of the refrigeration facilities, which are surely not tiny, was designed and the recycling of the worn-out machines returned by the customers is guaranteed.

Awards

BOLARUS is a flourishing company. It is no surprise that its quick development and high standards were appreciated by the organizers of the trade fairs. BOLARUS was honoured with a prize for the Best Exporter of EuroGastro Fair 2009 during the last edition of this trade in Warszawa. Other distinguished awards include the “Pantheon of Polish Ecology” under the Patronage of Environment Minister and the chairman of the Polish Centre for Testing and Certification for preparing and implementing EMS according to the ISO 14001 standard. In 2003 and 2005, BOLARUS was presented with the title of Gazelle

of Business for dynamic growth of the company by the editorial staff of the TV programme, “Puls Biznesu” (‘The Rhythm of Business’). Bolarus owns the ISO 9001 certificate. The products of BOLARUS received various certificates, namely, B, CE, GOST-R and NATO Commercial and Government Entity Code (NCAGE).

Target for the future

The company’s aim is to purchase the equipment providing greater quality and safety of the working environment. Additionally, there are plans to modernize the production buildings and storage facilities in order to conserve thermal energy and to improve comfort and organization of work. Up to this moment, a new warehouse was built and the surface production was extended to additional 1000 m², which contributed to good energy balance.

Quest for success

Success for BOLARUS is to meet the customers’ needs and requirements, to provide satisfaction to the clients and to establish trust in the company’s brand.

To achieve success, the firm responds quickly to the demands of the market, the latest trends, and the new technological solutions and constantly increases the quality of the products and service.

However, the employees from the refri-

HORECA Industry > Bolarus Księga1.indb 73

geration industry in Bochnia do not rest on their laurels and set themselves new targets as, to quote one of them, ‘success does not have a finishing line and we will always put effort to achieve it’..

Manufacturing-Journal 71 2009-10-06 21:47:16

OPENING UP NEW OPPORTUNITIES

FACT BOX FULL NAME: FAKRO Sp.z.o.o.

PRESIDENT: Ryszard Florek OPERATIONS: Consumer goods ESTABLISHED: 1991 EMPLOYEES: 3000 REVENUE: 1 mld zł

www.fakro.pl

F

akro is a worldwide manufacturer of roof windows that earned itself the reputation as the most innovative Chairman of the board Polish company.

Ryszard Florek Established in 1991 as a family business, the enterprise developed rapidly, entered overseas markets and easily won international renown. Today it has 15 percent of sales figures on the global markets of roof windows, which makes it the world’s vice-leader. The Fakro products can be found in forty countries. Aiming to supply the highest quality products and meet the requirements of customers all over the world, the company attaches great significance to the technological development, security and the environmental impact of the products.

Facts and figures

The company’s history reveals an undeniable truth how a small family business turned within eighteen years into a major global provider of roof windows.

Numbers speak for themselves. Initially a business consisting of one facility and several persons, Fakro grew enormously and today it employs a total staff of over 3000 and has fifteen branches located in many different countries, i.e.

72 Manufacturing-Journal Księga1.indb 74

the USA, UK, Germany, France, Holland, Russia, Ukraine, Hungary, Slovakia, China. The firm offers a wide range of roof windows: pivot windows, top hung and pivot windows, side hung escape windows, L-shaped windows, light tunnels, skylights, roof access windows and windows featuring smoke ventilation system. The offer includes also different accessories such as awning blinds, roller shutters, Venetian blinds, pleated blinds, blackout blinds, electronic control and smoke ventilation systems, light tunnels, loft ladders and many other products which add comfort to the loft. All products provided by Fakro are safe and modern solutions that incorporate the latest technological advancements. Windows feature the topSafe anti-burglary system. What is more, Fakro has its own R&D centre that patented many innovative solutions and applied for patents on other ones. As a result, the company brings not only roof windows to the world markets, but also creativity and technological solutions developed by Polish engineers and designers. In 2009 the firm’s upbeat attitude is likely to continue, as the year marked the launch of a new series of products. New products are always shown for the first time at the Budma fair in Poznań. This year the promotional offer includes FTH-V high pivot windows, FDH duet high pivot windows which are a perfect replacement for the combination of horizontal windows to provide more light space. The

FDH window was designed in accordance with the topSafe system. It uses a no-

Consumer Goods Industry > Fakro 2009-10-06 21:47:17

vel method of reinforcing the roof windows structure. Innovative techniques were applied in solutions relating to the fitting of hinges, the reinforcement of wood structure and transom elements.

An additional steel section in the lower part of the sash is yet another improvement. The windows show high resistance to burglary. Another product that belongs to that group is a balcony window.

The offer contains also self-assembly solar panels for roof slope or roof windows.

From then to now

Fakro has been operating on the market for almost two decades, but the idea to create this type of business is much older. As the company’s president, Ryszard Florek, reminisces “the origins date back to my childhood. When several times a year my family house in Tymbark was packed with guests, children slept in a makeshift bedroom in the attic. The light used to come inside through the glass tiles. Then I came up with the idea to replace them with hung windows in the roof.” Several years later, in 1976 Mr Florek went to West Germany where he le-

arnt that roof windows are practical and functional. At that time he decided to give this product attention in the future. Having completed his studies, in the mid-1980s he and his friend Jacek Radkowiak set up a woodwork factory “Florad”. At that time it was the largest privately-owned and the most innovative company in the communist Poland. Florad manufactured skirting boards, floors, wardrobe recesses, gates for historic buildings. All profits were invested in further development of the enterprise as well as in new machines. After Fakro was established in 1991, the production of roof windows started. Eighteen years ago Fakro consisted of several persons and manufactured one model of roof windows. Today it is the most innovative Polish enterprise that has 15 percent of the worldwide sales figures for roof windows. Thanks to its state-of-the-arts R&D centre it developed and patented myriad novel solutions. For the past twelve months only the company’s patent department has submitted fifteen applications for patent. Given the number of thirty people

who work within the group, the average equals approximately one patent per month whose development can be credited to two engineers. Mr Florek reveals that the enterprise prioritizes quality, innovation and development. “For me and for the board, it is of utmost importance to maintain the firm’s number two position worldwide, thus providing a long-term existence of the company,” he said. It is also worth noticing that, by operating on different overseas markets, Fakro vicariously contributes to building the prestige of the Polish economy. The development of the company is important, but the good prosperity of the region and country are also the objects of the firm’s activities. The company believes that the progress consists in creating new jobs, not only those involving work on assembly lines, but especially jobs requiring high qualifications, i.e. jobs for engineers, technologists, managers etc.

Eco-Fakro

Like most self-respecting firms, Fakro developed its own quality control policy which is conducted in consonance with European standards and which became an inseparable element of the production process. Apart from the fact that the company has prestigious quality assurance certificates, the enterprise has also respect for green issues. The firm’s ecological policy is easily noticeable in materials used for the manufacturing purposes. The main material is pinewood – a type of wood widely recognised as one of the most environmentally sustainable building materials. Fakro sources wood only from regions whose forests are properly managed, i.e. the volume of new planting is much greater than the volume of the material removed. Additionally, the company promotes the protection of the environment by developing environmentally friendly products, using ecological technologies, minimising and/or utilising any waste raw materials, reducing emissions to avoid contamination and reducing noise.

Coexistence vs. existence

In day-to-day business Fakro competes with other brands, e.g. Velux and Roto.

It can effectively compete with Roto, but the competition against Velux is more difficult because it has been maintaining a monopolistic position for almost forty years. In some Western countries it controls even 90 percent of the

Consumer Goods Industry > Fakro Księga1.indb 75

Manufacturing-Journal 73 2009-10-06 21:47:18

market and, as a result, offers the costs of distribution which are frequently 10 percent lower than those offered by Fakro. In cases where Fakro cannot provide competitive prices, it places emphasis on the enhanced quality and diversity of products. Sometimes the development is hard to achieve for Fakro, as Velux has enormous financial capital which is occasionally used in contravention of antitrust and competition law. For example, last year the European Commission examined the case brought against Velux concerning the overuse of its dominant position. The EC scrutinized the companyâ&#x20AC;&#x2122;s offices in Denmark and in other countries and, judging by a change made to discount offers, it must have called a halt to the firmâ&#x20AC;&#x2122;s dubious practices. On the other hand, from incipient stages of the activity, the top quality has been central to Fakro, hence the unrivalled quality of products that the firm can boast today. This asset frequently comes to serve as a bargaining chip that helps the firm stay one step ahead of the competitors. The Fakro products are the only products all over the world which have been honoured with the German quality and safety symbol TUV. Featuring the topSafe anti-burglary system and at least the third class of security, roof windows provide an excellent protection not only from cold or noise, but also from burglars. Furthermore, a healthy microclimate in a room and lower heating bills are possible thanks to special automated ventilators fitted in the Fakro windows. It is common knowledge to every entrepreneur that the customer trust cannot be won overnight. It is a longterm process that requires a lot of work and effort. From the very beginning Fakro has been investing in research and new technologies. Today it still works on expanding the range of products and implementing innovative solutions on regular basis. The business offer, which is diversified and comprehensive, makes competitors lag behind. And last but not least, given the growth in electricity and gas bills, one more point relevant to the manufacture of roof windows is energy efficiency that is possible owing to the optimal combination of professional and ecological manufacturing practices.

74 Manufacturing-Journal KsiÄ&#x2122;ga1.indb 76

Consumer Goods Industry > Fakro 2009-10-06 21:47:19

Quality –

SEST on the refrigeration market

SEST is the leader on European and Russian market of Chairman of the board refrigerating sysMr. Pier Luigi Faggioli tems. The company is a member of the group LUVE (www. luve.it). At the level of whole group SEST employs 450 people and its annual turnover reaches 60 mln euro. Since the beginning of its activity on the market, the enterprise’s aim has always been the best quality, brought together by wide technical knowledge and innovation in technological process. SEST operates in facilities in Italy - Limana (BL) but for few years it has been developing also in Poland, having opened an affiliated company in Gliwice in southern Poland in 2000. In 2007 SEST also expanded on Russian market by opening a factory in Lipetsk. Nowadays the enterprise has already consolidated position on the European and Russian industrial market.

cial refrigeration systems (like for example refrigerating counters or cabinets in supermarkets) and for cold stores. 80% of SEST activity consists in providing systems for the sector of commercial refirgeration, in which the firm is leader in Europe, particularly in components for counters and tables for supermarkets.

The philosophy which lies on the basis of the company consists in providing a customer with assistance and consultancy.

The enterprise puts an emphasis also on quality, regarding it the best way to success. What particularly distinguishes

CUSTOMER NEEDS – REASON FOR EXPANSION

The factory SEST LUVE POLSKA

SEST is the fact that the enterprise takes care of safe and trustworthy delivery of all products, supposingly in the name of the principle “a satisfied customer means a loyal customer in future”. It can be stated that in this kind of attitude towards the market SEST sees its chance for future. SEST has also developed a capacity of adopting oneself to customers’ expectations at individual level. Due to the use of innovative technology, the enterprise is able to ensure the highest quality of manufacturing process, of every product as well as of delivery net.

A specialized offer

Talking about the offer of SEST, the company refers that its flagship products are: heat exchanger batteries for industrial refrigerating and conditioning, and more precisely evaporators for commer-

Soldering copper nipples

HVAC Industry > Sest Luve Polska Księga1.indb 77

Manufacturing-Journal 75 2009-10-06 21:47:21

Development in Poland

Since 2000, which means from the beginning of activity in Poland, key decisions made by the enterprise were determined by geographical position of the factory. Because of a very good location, SEST LUVE Polska had an opportunity of development by enlarging facilities. Due to this enlargment the enterprise can now operate on the surface ecquivalent to 15.000 square metres.

SEST LUVE Polska admits that choice of the town of Gliwice as its headquarter in Poland was carefully thought out.

Taking into consideration particular requirements for investments, the company enumerates crucial factors which helped to take a conscious decision about location of facilities in Poland:

phase as well as in developing period.

• Good infrastructure An industrial zone of Gliwice was already provided with all required infrastrucure (gas, light, water).

All these factors helped the company to take a positive decision about investments in Poland.

How to gain customers’ confidence

As is has been already mentioned, the

• Good logistic centre From logistic point of view Gliwice allows the company to found itself in the centra of European continent, which approaches SEST to all its clients, not only those from Western Europe.

• High level of workforce SEST LUVE Polska emphasises that it found in Poland very well-qualified and prepared workers quite easily. These are the people with a very good theoretical and practical knowledge of their profession.

• Support from local authorities Local authorities showed a favourable attitude towards SEST’s investments in Gliwice, giving its support in the initial

76 Manufacturing-Journal Księga1.indb 78

company SEST has its own strategy towards European customers which corresponds very well to a modern need of having own needs recognized in an

individual way. The Italian company developed this capacity to perfection.

SEST offers to its customers services and collaboration from the beginning – during the planification, through defining all technical and quality requirements, in order to complete the service with fast delivery, because only full service can satisfy clients so that for a long time they still will choose SEST. Apart from satysfying customers’ needs, the company SEST aims at innovation and development, without which the enterprise cannot work properly. In accordance with its main princples, the firm points at developing the quality of products.

The company is convinced that a customer expects a product of high quality and at the same time a good price, that is why SEST offers competitive services.

The enterprise puts also an emphasis on “just-in-time” delivery. Thanks to it, the customer can reduce its own magazine (which means reduce costs) and at the same time provide a faster delivery to ist own final retail clients. This attitude confirms that for SEST the most important thing in activity is a customer, whose requirements determine its services.

According to the statements of SEST, a great success achieved by the company was caused by having opened its acitivity with very precise aims and having put a client in the centre of its philosophy.

It means not only thinking about offering him a ready product, but also technical assistance in developing always more and more advanced products which reduce the cost of final product.

HVAC Industry > Sest Luve Polska 2009-10-06 21:47:22

Employees – responsibility of success

Currently in the company SEST LUVE POLSKA work 160 people. As organization and work distribution is concerned, in order to maintain coherence in technical planning, the company decided to leave a headquarter of technical department only in one place, which is Italy. This decision was determined by wilingness to specialise even more, to centralize new experiences and not to disperse this activity in more places.

The present policy of SEST regarding human resources point at professional development of knowledge and skills in order to make all employees satisfied with their tasks as well as with remuneration. It is worth mentioning that SEST is convinced that a company can develop only when all staff agree about main philosophy, principles, policies, commercial strategies etc. A success is build up by the personnel who creates a team. That is the reason why this enterprise invests in training courses to provide employees with chance to improve one’s skills and capabilities. The company states that a principle reason to be proud of are its employees. Only thanks to their involvment SEST was able to obtain success at the European level.

Past, present and future –

manufacturing and logistic activity

During the last 5 years the company SEST has changed, developing always

more integrated and complete logistic service, which based on open orders and estimation updated every week.

Nowadays the most important customers for SEST are those who make with the company the higest turnovers, which very often coincide with their needs to purchase more advanced products and services. There can be enumerated some of principal customers of SEST in the sector of commercial refrigeration: Carrier-Linde, Epta Group (Costan, Bonnet Nevè; George Barker, etc.) Isa, De Rigo and in the sector of conditioning: Swegon, Trox, Lindab, etc. Talking about Polish market, the company SEST LUVE POLSKA gives its interesting opinion that during the last 5 years their Polish clients in the sector of commercial refrigeration have developed very fast and became competitive on the European market. It is worth mentioning that SEST LUVE POLSKA takes care not only of customers but also of natural environment and apply all recent norms referred to protection of nature which are currently in force. Having in mind future development, the company is convinced to be prepared to face new problems on international market. It has already been implemented a new policy to promote a 360° service for international customers with the aim to become a principal supplier of SEST’s key customers at worlwide level. Nowadays the company SEST supplies the same groups operating in different countries: Germany, Sweden, Hungary, France and Czech Republic and some others also in South America. Due to the fact

HVAC Industry > Sest Luve Polska Księga1.indb 79

that the biggest customers of SEST run their activity all over the world, the company is planning to expand more also in other continents, not only in Europe.

Award for quality

In Poland SEST LUVE POLSKA was awarded a prize “Gazele”. The efforts of the company towards innovation, high quality and satysfying consumers’ needs have been appreciated. The company was also given a certificate UNI EN ISO 9001:2000 which confirms the priorities and philosophy of the company.

According to them, the most important thing in activity of SEST is quality. Every reached success depends on pursuing these aims. It is worth noticing that since 2005 SEST has been authorized to cerificate its products with the mark UR, which permits to respect a norm in order to import goods to North America, Canada and South America, liberating and favouring activities required by the norm for the final customer. In order to summarize it can be stated that the company SEST is an enterprise which has a precise plan and clear vision of its own growth by investing more in Europe and also in other continents, but always maintaining as main princples satysfying needs of the market with a great respect to its own employees.

Manufacturing-Journal 77 2009-10-06 21:47:23

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78 Manufacturing-Journal KsiÄ&#x2122;ga1.indb 80

HVAC Industry > Sest Luve Polska 2009-10-06 21:47:24

FULL NAME: TEDEX PRODUCTION Ltd. PRESIDENT: Monika Gawrylak OPERATIONS: Chemistry, Oil & Greases Products, Eksploatation Fluids ESTABLISHED: 1996

QUALITY IN THE FIRST PLACE

FACT BOX

EMPLOYEES: 106 REVENUE: 43 000 000 Pln

www.tedex.pl

H

i g h quality and healthy competition in business as well as in sports are ideas which Promotion Director of Tedex many compaGroup - Monika Gawrylak nies aim at in daily activities. One of them is Tedex Production, a distributor of a wide range of lubricants and exploitation fluids for automotive and industry.

The company has been active on the Polish market since 1996. Currently, it has a significant share in transport and industry sectors in Poland and deals with a number of Polish Automobile Communication Companies. The list of customers includes also institutional clients like police or army as well as mining, milling, service and transport companies. Due to that, the sales figures of Tedex are incessantly increasing.

Growth and development

Tedex Production Ltd came into being in 1996. Since the time the main activity of the company has been production and distribution of oils, lubricants and exploitation fluids. The enterprise was established as a production back for Tedex Oil Ltd, which has been distributing lubricants in Poland since 1990.

At first, the focus of Tedex Oil Ltd was on selling imported products from Belgium and the Netherlands. Since 1996, the emphasis has been put on offering lubricants produced in Poland in cooperation with Tedex Production Ltd. – The establishment of Tedex Production was a natural consequence of separating a subsidiary from the parent company – says Mrs. Monika Gawrylak, the Director of Tedex Production. She adds that at the beginning of the economic transformation in Poland the number of available, high quality products was very limited. Tedex Oil, and later on Tedex Production, offered a competitive brand, which would sell very well and quickly gained the acknowledgement of the customers. In 2004 a thorough reorganization of the two companies took place.

Since the time Tedex Production Ltd has been not only the producer but also the distributor of lubricants. At the current moment, the company possesses its own blending plant in Tomaszów Mazowiecki in central Poland. The production capacity of the works equals 40 000 tons annually, whereas the storage capacity comes to 2 millions of liters. The factory includes as well a train siding and a tax warehouse. Two other works of Tedex are located in Żory in the southern part of Poland and in Stara Iwiczna, nearby Piaseczno. The latter is a 3 flo-

Chemicals Industry > Tedex Księga1.indb 81

or building of 4200 square meters of surface including 1000 meters of storage. The building is air-conditioned, monitored by a modern security system, has its own restaurant, 2 meeting halls, a motorization shop, service backstage as well as a repair workshop. It is worth mentioning that Tedex Production belongs to the group of the fastest developing oil companies of the last decade.

Quality and customer orientation

What has always played an important role in the activity of the company, has been the quality of the offered products.

Due to that, in the year of 2000 the com-

Manufacturing-Journal 79 2009-10-06 21:47:26

pany enforced the System of Quality Control Management ISO 9002. Since 23rd October 2003, Tedex Production Ltd has been functioning in line with the re-

quisites of ISO 9001:2000. The fact that the company sells products and services of highest quality is the reason why it is perceived as a solid and reliable business partner. Tedex products enjoy good opinion among a wide range of customers: car users, service stations as well as large, institutional customers representing public transport, agriculture or building industry. Undoubtedly, the confirmation of the quality orientation is sales figures for lubricating and oil products of Tedex – they increase year by year. The success on the market can be then perceived as a derivate of the quality focus.

Oil production of Tedex is based on: • state-of-the-art technology, • additives from reputable producers (Chevron, Ethyl, Lubrizol), • base oils from PKN Orlen, Lotos Group S.A. as well as many other imported from best refineries of the world, • system of quality assurance in line with world as well as Polish procedures, among them ISO 9001:2000.

At Tedex the quality control starts from the very purchasing process. The suppliers of Tedex Production are best world producers of synthetic oils, coolants as well as national producers of brake fluids, screen washers and plastic greases.

Very good quality of raw-materials, modern technologies used in the manufac-

80 Manufacturing-Journal Księga1.indb 82

turing process as well as the expertise of s p e cialists working at Te d e x guarantee very g o o d using properties of oils delivered by the enterprise.

Another certifying factor are the requirements of Polish oil market and its customers. However, Tedex Production does not rest on its laurels. The company is incessantly improving its products and production processes according to technology novelties introduced by its American and western European counterparts. Furthermore, the company would like its customers to rely on its products. This is why it does not stop to make the manufactures, technologies and quality better. In fact, customers are the other focus of Tedex. Constant contact with the clients is guaranteed by an extensive trade-distribution net on the whole territory of Poland. It allows not only to develop the relations with the contracting parties but also to assure permanent supplies consistent with the customers’ needs as well as offer free technical service. The scope of the service ranges from professional advice concerning the choice of alterable oils and greases to tips and hints on their use and lubricating techniques. All that causes that after more than 10 years of business activity Tedex can guarantee high and stable quality of oils, greases and exploitation fluids, constant supplies

and their punctuality as well as competitive prices and cooperation terms.

Trainings and expertise

As far as the personnel policy is concerned, the company pays great attention to the knowledge and skills of its people. At Tedex it is believed that expertise and professionalism of the human capital can guarantee strong competitive advantage among the competitors.

– We offer our employees two types of trainings: marketing and technical. The first kind develops their negotiation skills, allows them to get to know the techniques of customer service, etc. The second type of trainings has a technical characters and is organized in cooperation with scientists from the Radom University of Technology – says Mrs. Gawrylak. Owing to a strict examination procedure, the employees of Tedex are one of the best experts on the market, acquainted with the latest developments of the industry and the market.

Extreme offer

At the current moment the offer of Tedex Production includes around 100 products. The range of the manufactures is impressive – the offer of the enterprise can interest companies representing various industries and branches.

The manufactures of the company include among others: oils for food industry, agriculture and forestry, form oils, hardening oils, oils for automatic and mechanic gears, air compressors and hydraulic systems, gear oils and engine oils for trucks, turbi-

Chemicals Industry > Tedex 2009-10-06 21:47:28

ne oils, sailing oils, cooling systems fluids, brake fluids or plastic greases. – As far as product management is concerned, we concentrate on the novelties and the most exclusive, top quality products – claims the Director of the company. One of the new positions in the offer of Tedex are sports oils. The series is introduced on the market at the current moment and is dedicated to sports, professional and racing purposes. – The series is called Tedex WRC. It includes three types of products: Tedex WRC Racing for tuned-up vehicles, Tedex WRC Speed for owners of civil cars and Tedex WRC Rally designed for vehicles participating in rallies and other events of this kind – says Mrs. Gawrylak. The newest series of the company is a unique manufacture. It is characterized by the best, world-class quality and due to that it has very few market counterparts. In fact, there is only one company producing oils similar to Tedex WRC. Yet, the greatest sales figures are generated by another product of Tedex Production – Tedex Universal. The product is appropriate for four-stroke engines with spark ignitions in cars and trucks fed by petrol or LPG gas working in hard conditions, for example city conditions when cars are stopped and moved often. This type of oil is also good for long distance drive.

Engagement in sports

As one of the best producers of sports oils, Tedex actively supports the events and teams of the car sports in Poland.

The company has been involved in the sponsorship of various teams since 1993 and distinguished with the Championship of Poland in N group for four times. The list of competitors cooperating with Tedex is long and includes

Górski and many others. Next to that, the sports activity of Tedex has included patronage of Krynickie Hockey Society and supporting young football talents.

International cooperation

The products of the enterprise are available not only on the Polish market – the company has been active on foreign markets for several years. One of the overseas branches of the enterprise is located in Lviv, Ukraine. – The cooperation has been functioning well and is developing, yet we do not perceive any significant growth in sales – claims the Director. According to Mrs. Gawrylak it derives from the difficulties in the cooperation. – It refers first and foremost to administrative costs connected with the

delivery of the products on the territory of Ukraine – she points out. The company can also boast successful cooperation with a dealer in Slovakia and Kazakhstan. What is more, Tedex is trying to reenter the Lithuanian market. The enterprise cooperated with one of the Lithuanian distributors some time ago. However, the cooperation did not succeed and Tedex terminated the agreement. At the present moment, the negotiations are revived and it is possible that they will result in starting the partnership once again. Without doubt, the possibility of a new market, stable sales figures of the industry, top quality of the manufactures as well as employees’ expertise and a wide range of products assure that the future of Tedex is more than bright.

among others: Robert Herba, Artur Skorupa, Andrzej

Chemicals Industry > Tedex Księga1.indb 83

Manufacturing-Journal 81 2009-10-06 21:47:29

EXCELLENCE STEEPED IN HISTORY AND TRADITION

FACT BOX FULL NAME: Fabryka Aparatury Pomiarowej „PAFAL” S.A. PRESIDENT: Chairman of the board Mr. Bohdan Wierzbicki OPERATIONS: Measurement and Control ESTABLISHED: 1897 EMPLOYEES: 436 REVENUE: 94 400tys. zł

www.apator.eu

P

afal is the biggest manufacturer of phase electricity meters in Poland. The Pafal brand is very well-known on foreign markets, as it can boast a long tradition in the power supply industry reaching back to the end of the 19th century. An integrated management system complying with PN-EN ISO 9001: 2001, PN-EN ISO 14001: 2005 and Accreditation Certificate authorizing the company for verification of electricity meters within the EU are great assets which ensure excellent quality of Pafal products.

Moreover, in 2008 the company was granted Module D certificate (the socalled MID). In 2004 the enterprise was incorporated into the Apator Group, the biggest Polish capital group operating on the market of switchgear and measuring apparatus, of which it is currently one of the member companies.

Flashbacks from the past

The origins of Pafal date back to 1897 when a branch of the German factory H. Aron Elektrizitätszähler-Fabrik, GmbH, was established in Świdnica, Poland.

It manufactured clock mechanisms for electric meters and by 1900 it had produced already all parts for meters, which were later assembled in Berlin.

After World War II the factory reached an important milestone. The facilities were officially taken over and became the state property. The factory was

82 Manufacturing-Journal Księga1.indb 84

also renamed Fabryka Liczników i Zegarów Elektrycznych (Factory of Meters and Electric Clocks), thus being given the first name in Polish. Since 1945 the plant, using machines, equipment and properties abandoned by the Germans, has continued manufacturing of meters and metering equipment. It started with the manufacturing of EFK-1 single phase meters. The manufacture of own parts and subassemblies for the meters started in 1947 and in the following year a hundred thousandth meter was produced. The manufacture of a new model A2 type and C1 type three phase meter single phase meter started two years later. The enterprise also began to receive numerous orders from abroad, e.g. Romania, the People’s Republic of China, Turkey, Egypt, Brazil, Iran, Greece, Iraq, Yugoslavia, Bulgaria, Pakistan, Yemen. Though the name of the company changed several times, the manufacturing profile remained intact, focusing chiefly on electricity meters. In the 1950s the enterprise received an offer from India requiring the manufacture of meters compliant with the British standard. In the aftermath of the order, the manufacturing of new A3 and, subsequently, A4 type single phase meters started in 1958. The 1960s marked the beginning of a particularly intensive development of meters’ design that has been continued to date.

For example, A5 type single phase and C3 and C5 three phase electricity me-

ters were launched in the 1960s. Their design complied with strict quality requirements of Polish, British and Brazilian standards. In the second half of the 1980s, within the development of the design, an automotive assortment was expanded to include sensor sets and car sensors for passenger cars, vans, lorries, etc. As regards the basic assortment, i.e. the electricity meters, new versions were launched, e.g. type C521, A522 and 5A22m three phase meters in casing with complete insulation and also with magnet bearings. In the early 1990s the enterprise, after being privatized, saw another change of business name. Since that time it has been using the present name Pafal. Towards the end of the 1990s new inductive electricity meters of 6A8 and 6C8 types, electronic meters and other products such as DATAPAF and WATPAF registers of electricity and power and PCP time switches became part of the production. Currently, Pafal electricity meters comply with requirements of IEC international standards such as DIN and VDE German standards, BS British standards and Polish standards. In 1992 electricity meters manufactured by Pafal were granted a German certificate. It was a watershed that allowed for selling Pafal products in Germany and within the European Union. The business thus joined the elite group of the European manufacturers of metering equipment. Engineers and technicians put a lot of effort in order to

Measurement & Control Industry > Pafal 2009-10-06 21:47:30

attractive employer. Pafal takes on highcaliber university graduates looking for employment in the power supply industry. All employees work in a friendly and flexible environment. For example, they work flexible hours and take part in training courses, some of which are funded by the EU. Moreover, Pafal tries to integrate people by organizing various events for whole families such as Children’s Day or St. Nicholas’ Day.

Defining the Principles of Inte-

design special versions of electricity meters that would meet the requirements of customers both in Poland and abroad.

At the beginning Pafal offered only one type of single phase meter, whereas today it manufactures the whole family of top quality electricity meters.

the product. By doing so, the manufacturer wants not only to customize the product, but also offer professional advice on how to use efficiently all of its capabilities (remotely-controlled meter reading, wireless data transfer). When it comes to employment opportunities, the enterprise has what it takes to be an

grated Management System

Pafal developed and implemented an Integrated Quality and Environment Management System which is applied to virtually all areas of the firm’s activity. The major goal pursued by the quality management is to come up to the customers’ expectations by providing top-of-the-range products which are

Profile

The company’s profile focuses on two areas: manufacturing and services.

Manufactures include: • Metering devices, particularly oneand multi-phase electricity meters; • Recording devices; • Power settlement systems; • Plastic accessories.

Services: • Professional examination of metering devices, particularly one- and multi-phase electricity meters; • Repair and verification of one- and multi-phase electric energy meters; • Metering equipment service; • Varnishing of (metal) components; • Technical measurements; • Mechanical working (cutting, bending).

Geared towards people

Pafal owes much of its success to a strong human potential. As the company admits, if it had not been for the commitment and creativity of employees, the business would not have been able to achieve its primary goal, i.e. satisfaction of customers’ needs. In day-today practice Pafal follows a generally flexible policy, getting the customers involved in the process of designing

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manufactured in line with ISO 9001: 2000 and are also compatible with legal requirements and EU directives. In those areas a task-based approach is normally adopted. It is oriented towards research and development of new products, elimination of incompatibilities and quality improvement as well as co-operation with suppliers. A modern management policy is, on the other hand, connected with eco-friendly approach.

It entails acting in accordance with ISO 14001: 2004, improving the manufacturing process by reduction of adverse influence on the environment as well as implementing eco-friendly methods of developing new products. Taking into account the above principles, Pafal attaches great significance to the reduction of harmful substances, reduction of emissions to the atmosphere, reduction of the amount of waste products, use of recyclable materials and conformance with legal requirements pertaining to the environmental protection. Improvement of workersâ&#x20AC;&#x2122; skills and abilities is a crucial factor that allows for efficient performance of the Integrated Management System. Employees are, therefore, given opportunities to take part in training courses. The enhancement of the system is possible due to joint effort of all employees which is based on the Plan-Do-Check-Act four-step problem-solving process. This kind of policy provides a framework for setting goals and undertaking tasks related to the quality and environment management.

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The pig with no poke

Pafal has a wide array of certificates which attest to both the high quality and reliability of its products, so the investment in the Pafal products is not like buying the proverbial pig in a poke.

First of all, the manufacturing process is conducted following the guidelines of certified quality management system. By the end of 2006 the company had been granted Integrated Management System Certificate ensuring compliance with ISO 9001: 2001 (quality management) and ISO 14001: 2005 (the management of the environment). Furthermore, Pafal implemented a quality management system in its laboratory (ISO 17025: 2001) and, as a result, was

granted, by the Polish Accreditation Centre, Accreditation Certificate covering the scope of calibration of electricity meters within the EU. The company can also boast the prestigious title Gazele Biznesu 2007 (Business Gazelles) awarded to Polish businesses which show good financial results and sustainable growth. The manufacturer was awarded the title two times in a row. Other prizes that Pafal was honoured with include Filary Polskiej Gospodarki (Pillars of Polish Economy) and Przejrzysta Firma (Transparent Company). In the era of globalization the certified quality and compliance with international norms undoubtedly add luster to the product.

At present Pafal is a supplier of electricity meters to the EU member states, Eastern countries and South America. It acts chiefly via independent distributors but it also has some experience in direct investments. The company looks set to increase its share on the electricity meters market worldwide. For this reason, it is searching for overseas business partners that would be willing to joint Pafal in its pursuit of international success.

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