GEBHARDT-STAHL commissions a new profiling machine

Werl. GEBHARDT-STAHL - the steel section specialist, is preparing itself for the future with a new profiling machine. Following an increase in demand for thermally separated reinforcement sections (up by some 30 % since mid-2010) the family-rooted Werl-based company is investing a high six-figure sum in the new machine. With the help of the machine which possesses the latest digital control technology, GEBHARDT-STAHL is able to increase its total output by around 15 % a month, i.e. approx. 600 t. of steel. Through this expansion to the production capacity, the already very short delivery times can be scaled down further. In the manufacturing process, the purchasing of the new machine will accompany a further increase in flexibility as well. As Managing Director, Ralf Neuhaus states: “At our site in Werl, we now have a total of eight profiling machines in operation. This way, we can process our orders quicker and set new benchmarks in terms of reaction speed.” At the start of April, the machine will enter service in the new 4,500 m2 production hall in Runtestraße.

On the machine, which has been designed in-house by GEBHARDT-STAHL over the past half year, sections can now be produced nun with even greater precision than has been the case up until now. In so doing, section lengths length tolerances are adhered to precisely (up to a tenth of a mm). In principle, nearly all sections from GEBHARDT-STAHL’s wide range can be produced on it: both coupling sections / perforated sections as well as structured unrolling sections.

Besides the commissioning of the new machine, the increased demand for thermally separated reinforcement sections for plastic-framed windows also brings joy to those in charge of the family-based business. Using so-called thermal separation technology, GEBHARDT-STAHL combines plastic and steel in reinforcement sections in such a way that the thermal conductivity of the metal section is blocked. However this has no effect on the rigidity and strength of the reinforcement section. With the help of the innovative section of high insulation values are achieved without having to sacrificing stability. As Ralf Neuhaus states: “Increasingly, we see that window manufacturers have recognised the signs of the times and are happy to order thermally reinforced sections from us. As such, they can look forward to the Energy Saving Ordinance of 2013 with confidence.”

The Energy Saving Ordinance (EnEV) of 2013 will again significantly tighten the Energy Saving Ordinance from 2009. As such, there will be stricter requirements to do with the energy-related quality of new buildings and the modernisation of older buildings. Compared to the Energy Saving Ordinance of 2009, the energy requirement for heating and hot water in inhabited and non-inhabited buildings should fall further - by almost 30 %. As Neuhaus stresses, “With the favourable properties of our sections however, this isn’t a problem”. In the long run, the thermally separated GEBHARDT-STAHL products can squeeze the UF-value by 0.1 to 0.2 points, even with the same structure. This is something which is favourable in terms of CO2 output and heating costs. As Neuhaus adds: “Even with existing window systems, heat conductivity can be reduced by up to 20% with the new technology. The condition for this is merely that the conventional reinforcements are replaced by our new thermally separated ones.”

GEBHARDT-STAHL has now developed the technology to manufacture thermally separated sections for over 30 window shapes and/or window variations. In addition, the company has been active in gaining new expertise for the demanding task of section production. As company representative, Dirk Thörner states: “We will try to reduce the manufacturing costs for these high-end products further still. When we manage to do this, we will of course pass the benefits onto our customers.”

In fact, the company’s good reputation in thermally separated sections extends beyond Germany’s borders. Recently, a well known system manufacturer from the French window industry visited the Gebhardt-Stahl factory in Werl. At the end of the year, the company plans to launch a new development. More detailed negotiations with GEBHARDT-STAHL are currently underway.

The French negotiating partners were also impressed by GEBHARDT-STAHL’s courteous customer service staff. With regard to thermally separated sections, since the start of the year, the company has been able to address customer suggestions in much more detail and in addition, manufacture substantiated drawings, structures and Flixo calculations.