02/07 Nominal Charge 2,00 EUR HYDRAULIK - … ISSUE FEBRUARY 2007 The managing directors Uwe Buschmann Thomas Armerding Dear reader, HANSA-FLEX has had a successful year. That claim

Partner of the branchHANSA-FLEX Hydrauliccomponents

Page 12

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HYDRAULIKPRESSE

20

Issu

e 1/

2007

Recycling down

to perfection

HAMMEL masters its

mountains of waste

02/07

Flirting with

public transport

Stadler puts its

faith in trains

04

06

Bau-ABC

Rostrup

Training centre nearby

Zwischenahner Meer

is the future

HYDRAULIKPRESSE

Editorial 03

Flirting with public transport – Stadler puts its faith in trains 04

Commercial effi ciency requires an educated workforce – Construction training is the future 06

Poster: XWORLD TOUR 08

In conversation with Volker Brosius – Thinking in red-and-white 10

One for all – HANSA-FLEX Hydrauliccomponents 12

HANSA-FLEX France – Like a phoenix from the ashes 14

HANSA-FLEX Oyten: On-the-job motivation – Changes at the workplace 15

Out through the roof – “That bit of extra commitment“ 16

HANSA-FLEX donates to SOS Children‘s Village 18

DIN EN 14001 – More environmental protection and improved profi tability 19

Recycling down to perfection – HAMMEL masters its mountains of waste 20

HANSA-FLEX shareholders‘ meeting – The founding generation steps aside 22

Prevention starts early – Give out only factual information 24

Quiz, training sessions, trade fairs 26

Literature, fi gures & facts, preview 27

INHALT | IMPRESSUM

Inhalt

02ISSUE FEBRUARY 2007

13th VOLUME

Editor:

HANSA-FLEX Hydraulik GmbH

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Phone: 0421 - 48 90 70

Fax: 0421 - 4 89 07 48

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Horst Otto (PAPP Werbeagentur)

Layout: Nadine Staciwa

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available at our Website.

HYDRAULIKPRESSEISSUE FEBRUARY 2007

The managing directors

Uwe Buschmann Thomas Armerding

Dear reader,

HANSA-FLEX has had a successful year. That claim is backed by the impressive fi gure of 6.5 million metres

of hose shipped from the central warehouse to the HANSA-FLEX branches and cut to local market needs in

the last year.

HANSA-FLEX is growing rapidly, and its close attention to customer needs allied to outstanding reliability

are key factors in that trend. In the past year, 2006, we opened 23 new branches in Germany and abroad.

Other new branches are scheduled to expand the tight-knit network even further in the course of 2007. The

concrete benefi ts this will deliver to our customers, and how they can be utilized to the full, are demon-

strated by the example of HAMMEL Recycling on page 20 of this issue. HAMMEL relies fully on the support

of HANSA-FLEX in providing its own service back-up. The people at HAMMEL know that there is always a

branch somewhere close by!

A key factor in our close attention to customer needs is our FLEXXPRESS fl eet. This year the fl eet’s drivers will

be further upgrading their hydraulics know-how in collaboration with the ‘Bau-ABC Rostrup’ building acad-

emy. Bau-ABC, presented in more detail on page 6 of this issue, is an extensive, state-of-the-art training

centre for the construction industry, off ering all the facilities required to provide full qualifi cation of techni-

cal staff . The training centre maintains close partnership links with construction machinery manufacturers,

ensuring students are always taught on the very latest machinery featuring state-of-the-art technologies.

The fi rst FLEXXPRESS technicians have already made use of the facility to broaden their hydraulic engineer-

ing know-how and so provide our customers with the best possible levels of service.

We also look ahead to a fascinating new feature taking us beyond the demanding everyday work envi-

ronment, in the X-WORLD project. We will be revealing just exactly lies behind it in the next issue of

HYDRAULIKPRESSE.

We would like to take this opportunity to express our heartfelt thanks to longstanding HANSA-FLEX share-

holders Peter Weidtkamp and Rolf Hellmann, who offi cially retired on the occasion of our shareholders’

meeting last November. Their eff orts and commitment have been key to the development of HANSA-FLEX

into a system partner in all matters hydraulic. Now the younger generation is called upon to maintain and

build upon their work.

FOREWORD

Editorial

03

ISSUE FEBRUARY 2007

Increasing traffi c jams on the roads, rising fuel and

road tax costs, stress and bad weather are combining

to drive commuters increasingly onto the railways.

Suburban light rail, underground and regional rail

networks are the way ahead in terms of public trans-

port solutions. Since the end of the state railway

monopoly in Germany, private transport companies

have been fl ooding into the sector.

The Stadler company in Pankow near Berlin is prof-

iting from that trend. Rolling stock for suburban

light rail, underground and regional rail networks

has been built at the site, one of Europe’s most

state-of-the-art assembly plants, since 1996. In

the year 2000 the plant became part of the Swiss-

based Stadler Rail Group. Since 2004 the young, dy-

namic company has been building the new model

of regional railway traction unit named FLIRT, and

in doing so has relied on the pipes and tubes know-

how of HANSA-FLEX.

The FLIRT model built at Stadler Pankow is an ex-

tension of the existing Stadler Rail Group range fea-

turing the Regio-Shuttle RS1 and the GTW, in both

electric and diesel-electric designs. The Group oper-

ates at seven diff erent locations, and specializes in

trains for regional and suburban rail networks, un-

derground systems as well as trams, and in Switzer-

land also builds cogwheel railway trains. The Swiss

group off ers complete train concepts, employing

high- tech methods, light-weight construction

and service-friendly design, all aimed at helping

the transport operators to cut operating costs and

minimize the cost of energy and maintenance. The

modular concepts are tailored to rail operators’ spe-

cifi c needs, and are one of the major factors in the

success of the Stadler Rail Group.

The latest example is the FLIRT (Fast Light Innova-

tive Regional Train), based on a new-style modu-

lar construction method enabling it to be easily

adapted to the varying capacity requirements of

transport companies. The trains can be supplied in

various sizes and designs according to the operators’

needs. Stadler received its fi rst order for 42 FLIRT

units in 2002. The batch was ceremonially handed

over to the Swiss Railways SBB in 2004. The FLIRT

has been a big hit ever since.

Modular constructionson cushions of air

The FLIRT’s attractive features include air-condi-

tioned interiors and generously proportioned mul-

tifunction compartments in the entrance areas. The

passenger compartment is stepless and free of bar-

riers thanks to a special confi guration of air-sprung

power and carrying bogies. It off ers clear passage

all through, which means it can also be used by

passengers with bulky luggage, bikes, prams and

wheelchairs. Large doors and slide-out steps pro-

vide comfort entry and exit.

Stadler Pankow GmbH designs, develops and man-

ufactures rail vehicles. On a total area of 15,000

square metres, rolling stock for underground sys-

tems and trams and suburban light rail and regional

rail network trains are built on parallel lines. All the

operations are housed under one roof. Complete

vehicles are assembled to customer specifi cation

from bought-in components. The assembly process

begins with the arrival of the bodyshells. They are

conveyed by a universally usable air cushion system

to the assembly stations, where all the components,

such as the air conditioning, drive gear, interior fi t-

tings and cab are installed. State-of-the-art crane

installations enable heavy items and materials to

be moved around. In order to utilize special manu-

facturing methods such as the bonding technique

employed on the Regio-Shuttle, the assembly hall

in Pankow is conditioned to a temperature of 20

degrees Celsius and 40 percent humidity. Extrac-

tor units ensure the working environment is free of

pollutants.

Flirting with public transportStadler puts its faith in trains

RAIL VEHICLES

04 HYDRAULIKPRESSE

From the drive gear to the brakes

The HANSA-FLEX Henningsdorf branch has been

supporting Stadler Pankow for six years now. Sales

executive Detlef Ströming maintains close contact

with his customer, because he believes in providing

intensive service. HANSA-FLEX works closely with

Stadler designers right from the prototype develop-

ment stage, so as to devise the optimum solutions

even for sudden new requirements in quick time.

HANSA-FLEX supplies pipes to ensure the safe trans-

portation of fl uids on the FLIRT units. This means

more than just hydraulics. The trains’ piping sys-

tems – most of which are of curved design – carry

oil for the engine’s oil coolers, water for the toilets,

or compressed air for the high-performance brakes.

All the tubing serving as safe housing for the trains’

cable harnesses also comes from HANSA-FLEX.

The right solution:stainless steel

All pipes used by Stadler are now made of stain-

less steel, thereby avoiding galvanic currents. Such

currents occur when diff erent metals, such as brass

fi ttings and stainless steel pipes, come into contact.

Because all the pipework and fi ttings are supplied

in stainless steel, corrosion in the various systems

is much reduced.

This search for the optimum solution based on the

full extent of the know-how resources available is

characteristic of the highly professional relationship

between Stadler and HANSA-FLEX. As part of that

relationship, the Henningsdorf branch provides the

customer with access to all HANSA-FLEX functions,

services and special departments. All processes are

coordinated from Henningsdorf by Detlef Ströming.

The advantage for the manufacturer is not only that

it is assured of on-time deliveries, but also it has

just one point of contact to deal with, and receives

just one invoice. This enables Stadler to optimize its

processes in one purchase, and all it needs to do is

make sure it orders parts lists in good time so as to

ensure everything runs to schedule. The piping sets

are then made at the HANSA-FLEX pipe-bending

centre in Schönebeck based on the just-in-time sys-

tem. That is also where the special hose solutions

are produced. These fl exible hose lines are used for

the train’s essential connections from car to car. The

hoses are able to demonstrate the full scope of their

strengths in these applications. The large number

of fi ttings required by Stadler also poses no prob-

lem; they are available at HANSA-FLEX ready to ship

at all times.

Popular FLIRT

The fi rst FLIRT featuring HANSA-FLEX pipes and

hoses rolled off the Berlin production line in May

2006. Since December 2006, 20 trains of this type

have been operating on the regional lines of the

North East-Hesse network. This model makes it an

attractive proposition for anyone to fl irt with the

regional rail network.

05

RAIL VEHICLES

ISSUE FEBRUARY 2007


At the outdoor site close to the Zwischenahner Meer

lake in Bad Zwischenahn, bore holes are being dug.

In a large training centre nearby young construction

industry apprentices are making pavements using

natural stone, while others in the roofed outside

area are installing sewage pipes under building site

conditions. The ‘Bau-ABC Rostrup’ building acad-

emy teaches the full range of construction industry

trades.

Work on building sites is going through a period of

change. In view of the ever more complex machin-

ery and materials involved, construction industry

trades are increasingly demanding high-tech train-

ing. “The level of technology now employed in the

construction industry is huge, so comprehensive

training is more important than ever”, asserts Emke

Emken (Dipl.-Ing.), director of Bau-ABC Rostrup,

underlining the rate of change in the construction

industry trades and the resultant key role of the

more than 200 training centres in the German con-

struction industry.

Bau-ABC Rostrup is one of the largest centres of its

kind, training 1,300 apprentices a year in cross-com-

pany courses using state-of-the-art equipment and

systems. The cost of the training courses is borne by

all construction companies by way of a levy. This

fi nancing system enables the training centres to

provide virtually cost-neutral training services.

The operations of Bau-ABC Rostrup are rounded off

by courses for site specialists and managers, such as

overseers and master masons.

Roadbuilding under shelter

All over the 75,000 m2 Bau-ABC Rostrup site it is

a hive of activity. In training workshops for wood-

working, dry-stone and concrete construction and

pipework, and in the outside areas – parts of which

are also roofed – where training in specialist foun-

dation engineering, well-drilling and roadbuilding

is taking place. There’s digging and excavating,

trowelling and concreting going on all around. Even

complete asphalt roads are being laid. Training is

given in all fi elds and on all machinery, whether

for sewage pipe installation, general earthworks

or roadbuilding. And because practical know-how

and theoretical knowledge go hand-in-hand, class-

rooms with state-of-the-art facilities are attached.

At Bau-ABC Rostrup students learn how to perform

specialist construction jobs, as well as how to han-

dle challenging materials and use the ever more

complex, and often computer-controlled, construc-

tion machinery. Bau-ABC Rostrup provides special-

ist training for machinery operators, because only if

machinery is properly deployed can site operations

be carried out effi ciently and cost-eff ectively. The

extent to which construction work has changed

is demonstrated by the machines used to lay road

foundations. Nowadays they are laser-controlled

GPS (Global Positioning System) guided units of

which the jaws are held at a constant level by way

of electronic pulses.

Alongside the 40 staff of Bau-ABC Rostrup, over

400 part-time tutors are variously in attendance to

convey their extensive knowledge. The teaching re-

source also includes tutors from HANSA-FLEX, such

as Carsten Kempfert from the HANSA-FLEX training

centre, teaching courses on the subject of pipes and

fi ttings. After all, hydraulics is a key part of the con-

struction business.

FLEXXPRESS service techniciansextend their know-how

HANSA-FLEX not only deploys teaching assistance

to Bau-ABC, it also utilizes the training resources for

its own learning needs. As part of that regime, a se-

ries of seminars for FLEXXPRESS service technicians

to extend their know-how in mobile hydraulics

has been scheduled for 2007 with Hermann Greve,

head of machinery and metals at Bau-ABC Rostrup.

A number of three-day practical courses, attended

by between ten and twelve participants, have al-

ready been held.

Commercial effi ciency requires an educated workforceConstruction training is the future

BAU-ABC ROSTRUP

06

The ‘Bau-ABC Rostrup’ building academy in Bad

Zwischenahn, in the German state of Lower

Saxony, was opened in May 1978. The training

centre has a total of 10,500 m2 of roofed teaching

area in 16 teaching halls as well as 20,000 m2

of outdoor training space. Alongside 20 seminar

and group-work classrooms off ering state-of-the-

art teaching facilities and Internet access, it also

houses a concrete lab, a pumping and fl ushing

systems lab, construction machinery control

simulators, a surveying and measurement systems

training room, a PC training centre and a number

of other specialist teaching and demonstration

rooms. Construction machinery training is housed

in a large-area hall with space for simultaneous

tuition on up to four road-laying machines as well

as two multifunctional teaching rooms, each with

capacity for 40 students.

On building sites, in particular, it can easily happen

that a FLEXXPRESS service technician is confronted

by a construction machine in need of repair and is

forced to control the machine’s functions himself in

order to carry out his work. In such cases it is use-

ful if he is experienced in operating excavators,

crawlers or even asphalting machines. In addition

to those control capabilities, troubleshooting is also

taught. “Because, as the term suggests, our cus-

tomers expect our express hydraulic service to pro-

vide rapid assistance. When unexpected hydraulic

breakdowns occur it’s a race against time to ensure

that our customers are quickly able to resume their

operations”, says the head of the FLEXXPRESS Ger-

many fl eet, Mirko Kruslin. “So it‘s useful if our serv-

ice technicians are also comprehensively trained in

mobile hydraulics. Our relationship with the train-

ers at Bau-ABC Rostrup provides us with the ideal

support in achieving that.”

Bau-ABC Rostrup is also a member of the German

Confederation of Construction Machinery Engineers

and Master Tradesmen, VDBUM, and its partners

in training. Consequently, Bau-ABC Rostrup works

very closely with major construction machinery

manufacturers, among whom it enjoys high repute.

The machinery manufacturers provide their latest

generations of machines for use at the training

centre. This means not only can operators, agricul-

tural and construction machinery mechanics or in-

dustrial mechanics and mechatronics specialists be

trained on the latest models, but the manufacturers

can also utilize the impressive facilities at Bau-ABC

Rostrup to conduct in-house training courses or to

demonstrate the performance capabilities of their

machinery to customers and to instruct customers‘

personnel in operation of the machinery. Construc-

tion machinery manufacturer DYNAPAC for exam-

ple, known worldwide for its asphalting machines

and rollers, trains its customers and their machin-

ery operators at Bad Zwischenahn.

Apprentices in civil engineering also have the op-

portunity to operate the large-scale specialist

equipment at Bau-ABC Rostrup – an opportunity

not always open to them at their own centres. Con-

struction machinery operators have the chance to

learn how to use diff erent machine types. This is

one advantage which should not be underestimat-

ed, because many construction companies nowa-

days merely hire large-scale equipment for special

projects, so as to be able to deploy the machinery

more effi ciently.

BAU-ABC ROSTRUP

07

HYDRAULIKPRESSE8ISSUE FEBRUARY 2007

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4106040_TeaserXworldFeb_3rz_EN.i1 1 25.01.2007 7:51:57 Uhr

HYDRAULIKPRESSE10ISSUE FEBRUARY 2007ISSU

10

Volker Brosius was involved with hydraulics and re-

lated products as far back as his time as a motor me-

chanic at the Schönebeck diesel engine plant in East

Germany. When he began thinking about his future

career following German reunifi cation, HANSA-FLEX

appeared on the scene.

He and his brother recognised that in the Schönebeck

area, which was home to the former tractor plant,

freight carriers, construction companies and various

industrial concerns, there was a demand for hydrau-

lic parts and services. This idea led them to Heinrich

Grimpe in Elze. “Well, gentlemen, what’s holding

things back?” was Heinrich Grimpe’s response when

the brothers explained to him that they wanted

to open a HANSA-FLEX branch in Schönebeck. The

brothers fi rst began with a dealer in HANSA-FLEX

products in Schönebeck. When the establishment

of a HANSA-FLEX branch came under discussion,

the Brosius brothers were the fi rst point of contact

for Joachim Armerding and Klaus Böttger (who was

responsible for establishing new branches in the

Dresden area at the time). It all started on a humble

workshop site of the former LPG organization, as

Volker Brosius tells HYDRAULIKPRESSE.

: So your mentor was

Heinrich Grimpe?

Volker Brosius: He supported us in the early days,

visiting two or three times a week to go on local

customer visits round the area. This grew into a

close friendship. He provided tips and introduced

us to the possibilities off ered by the product range.

His approach was very proactive and go-getting,

believing you had to identify the opportunities on

the market and turn them into business. Not just as

a one-off , but with a view to keeping the customer

over the long term. As a result, the business quickly

established itself.

: You took his advice to

heart?

Volker Brosius: To cite one example: We had visited

Doppstadt Environmental as far back as December

1992, but it was not until 1993 that our eff orts bore

fruit, when their buyer, Mr. Neumann, made contact

with us. At that time the company urgently needed

screw fi ttings for a quick installation job. We were

able to deliver straight away, and that was the ma-

jor factor in our winning orders for other projects,

including orders to produce hydraulic hoses and

complete line sets. When the enquiry came as to

whether we could also make complete hydraulic

strips, with all components and connecting ele-

ments, we initially assembled them in the depot

yard, up until 1993 when we moved into the new

factory. Doppstadt is still one of the groups’ cus-

tomers today incidentally, and buys a wide range

of products and services.

: Following reunifi ca-

tion many businesses in the former East Ger-

many were rationalized; hydraulics expertise

was in demand.

Volker Brosius: For HANSA-FLEX that was the

motivation to turn itself into a system vendor. To-

day, alongside the branch, there is also the pipe-

bending centre in Schönebeck. The centre came

about because the local tractor plant was looking

to outsource its pipe-bending so as to optimize its

cost structures. It was agreed that our HANSA-FLEX

branch could carry out the jobs if we took on the

pipe-bending machines and the pipe-bending op-

erative responsible for it.

And the qualifi ed specialist we took on made such

a good job of it that more and more orders were

received from Germany and abroad. Soon the inter-

national HANSA-FLEX branches were also making

use of our expertise to help their customers ob-

tain bent pipes. Today our pipe-bending centre in

In conversation with Volker BrosiusThinking in red-and-white and acting in line with the customer’s needs

IN CONVERSATION

HYDRAULIKPRESSE 11ISSUE FEBRUARY 2007

Schönebeck is a specialist centre of competence of

the HANSA-FLEX Group, providing support to all the

branches, as well as off ering direct consultation to

customers from its pipe-bending specialists.

: You now head 20

branches and cover the largest sales territory.

How does that work?

Volker Brosius: After Schönebeck, branches

were soon established in Aschersleben and in

Magdeburg-Barsleben, where my brother Bernd

became workshop manager; they were followed

by Halle-Queis, Leipzig-Podelwitz, Leipzig-Taucha

and Salzwedel. Restructuring measures in 1998

led to the establishment of more branches. Six

FLEXXPRESS vans also belong to the group. It is not

the size of the territory that is decisive though. The

important thing is that all members of staff are

committed to the cause: thinking in red-and-white

and acting in line with the customer’s needs!

It’s not just the technical qualifi cations that need to

be right, but the personal qualities too. In short: the

chemistry must be right. It’s also about taking into

account regional mentalities and special circum-

stances in the various territories. That’s why we like

to employ local people.

: Is that why ‘Super-Illu’

magazine recently did a feature on you?

Volker Brosius: That was about the Combination

Pay initiative – starting pay to help the long-term

unemployed fi nd a job. We recruited a new member

of staff through the scheme, and drew from it some

highly positive benefi ts which might well be of in-

terest to other branches.

: How do you keep a

clear overview of such an extensive sales terri-

tory?

Volker Brosius: Transparency is important – in-

cluding in terms of the fi gures. I have all the key

commercial data for the management of branch

operations available online. The experiences of the

successful branches are made available as models

to all the others.

I also regularly visit the branches in person, and

support sales staff on visits to customers. Of course

we agree targets with the branches, and then em-

power staff to attain them – including by means of

courses at the HANSA-FLEX training centre.

: You also help others

achieve their goals?

Volker Brosius: I assume you’re talking about the

Kleinmühlingen Reed Orchestra, for whom we

sponsored new music stands and helped bring out

a CD. The links to the orchestra are longstanding; I

like the sound of reed instruments. They have also

played frequently at HANSA-FLEX events, and are

very popular.

: Your branches again

achieved substantial sales growth in 2006. Do

you see potential for more?

Volker Brosius: Indeed, especially as a result of

HANSA-FLEX’s development into a hydraulics sys-

tem partner. Provided we can bring home to the cus-

tomers our full range of products and services in an

even more closely targeted way, and demonstrate

to them opportunities to minimize interfacing and

maximize profi tability by using HANSA-FLEX. And

all that has to be delivered while maintaining the

consistency of performance and availability of their

hydraulic systems. That is where our opportunities

lie, to provide existing customers with even more

effi cient support and to win new accounts. We are

backed by the resources of all the HANSA-FLEX spe-

cialist centres of competence and are also capable

of handling industrial installation jobs.

IN CONVERSATION

HANSA-FLEX customers have long needed more than

just connecting elements for their hydraulics. They are

increasingly also asking for hydrauliccomponents. In

response to that demand, and as a hydraulics sys-

tem partner, HANSA-FLEX has established a dedi-

cated specialist centre of competence: HANSA-FLEX

Hydraulic Components (HKO), based in Weixdorf near

Dresden.

The unit is a key pillar of the HANSA-FLEX system,

and is represented externally by the HANSA-FLEX

branches and technical fi eld sales teams. HKO

provides the branch operations with new oppor-

tunities to off er their customers enhanced service

packages and to win new accounts. “Nowadays

customers expect hydraulic solutions all from one

source“, reports Tino Zeuner, manager of the spe-

cialist hydrauliccomponents unit. “Market experi-

ence also shows that the trend among medium and

large sized businesses is to reduce their supplier

base and interfaces in order to create lean process-

es – including in their accounting and controlling

systems.” Backed by the HKO specialists, the branch

staff are able to demonstrate their capabilities and

expertise in such specialist fi elds. Consequently, on

entering a branch customers encounter the whole

world of HANSA-FLEX systems.

An extensive rangeavailable to hand

HKO holds more than 3,500 diff erent hydrauliccom-

ponents in stock and ready to dispatch at any time

from its Dresden-Weixdorf warehouse. Hydraulic

cylinders in a wide range of confi gurations; pumps,

valves, tanks and fi lters, through to switches and

measuring devices, with the latest versions of all

items off ered in the range. 700 bar hydraulic sys-

tems are also supported with a selected range.

From this well-organized warehouse centre, 70 per-

cent of all enquiries can be handled directly. Special

items, or components outside of the HANSA-FLEX

range which need to be bought-in, can be procured

by HKO at any time. As an independent unit within

the HANSA-FLEX Group, HKO has its own purchas-

ing function, enabling it to manage its warehouse

stocks and keep them constantly refreshed. This

means rapid response is assured. All suppliers are

of course also ISO-certifi ed, so bought-in items can

be off ered in assured HANSA-FLEX quality. The HKO

staff in Dresden-Weixdorf regularly undergo train-

ing in the technical basics and on newly launched

products from the component manufacturers.

Staff even attend seminars held by competitors

in order to keep their know-how up-to-date. This

delivers inestimable benefi ts, because the world of

hydraulics is subject to continual change. Systems

are becoming more compact and operating pres-

sures increasing, and new fl uids, such as biogenic

oils, are being used. All of that demands continual

adaptation of the product range to ongoing devel-

opments.

From specialistto specialist

The HKO staff pass on their know-how in hydraul-

iccomponents to their colleagues at the branches,

because it is ultimately they, the branch staff , who

will be responsible for selling the components range

based on their skills as the initial point of customer

contact. Then, in consultation with the branch, HKO

makes direct contact with the customers in order to

turn their ideas into technical solutions. From spe-

cialist to specialist, so to speak, as HKO often deals

with customers’ own technical experts.

This often means a component confi guration meet-

ing all the customer‘s specifi cations, and at the

same time saving money, can be found more rap-

One for allHANSA-FLEX Hydrauliccomponents

HYDRAULICCOMPONENTS

12

HYDRAULIKPRESSE 13

RUBRIK

ISSUE FEBRUARY 2007

Überschrift

idly. Intelligent matching of cylinder confi guration

to motor power, for example, can possibly enable

standard components to be employed right from

the development stage of a unit.

Additional benefi ts in subsystems engineering

HKO also assists customers in dealing with their en-

quiries for complete units. These orders are passed

on to the colleagues at HANSA-FLEX Subsystems

Engineering (EAB) in Dresden-Weixdorf. Their

close-by location provides the EAB experts with fast

access to the highly specialized component stores,

enabling them to develop and assemble hydraulics

subsystems within a short space of time. It usually

takes just one to six weeks, depending on size of

order, from the initial layout through to commis-

sioning of an EAB subsystem.

Short delivery lead times – even for complex hy-

draulic assemblies – are becoming more and more

important to customers, and are a key pillar of the

HANSA-FLEX concept.

This cooperation has other advantages for custom-

ers. Their designs and development projects can be

supported by specialists from HKO and EAB from a

very early stage if so desired. This makes it possi-

ble to aid customers most effi ciently in delivering

their technical solutions based on the HANSA-FLEX

range. As a system partner, HKO is also geared up to

provide customers with prefabricated assemblies,

which are also delivered at the agreed time directly

to the point of installation. On request, HKO will

stock components and deliver them on a just-in-

time basis. This service also covers pre-assembled

valve blocks and valve combinations.

Special hydraulic cylinders

HKO utilizes its proximity to EAB when a non-stand-

ard hydraulic cylinder is urgently needed. EAB is

equipped with all the necessary machinery to off er

cylinders in special designs. And the sealing spe-

cialists in Eisenberg can also help out when seals

are needed. Their know-how is key to determining

the right sealing materials to be used in conjunc-

tion with chemicals, brake fl uid, water/glycol mix-

tures or bio-oils for example. The Eisenberg facility

holds some 7,000 diff erent seals in stock as part of

its standard range. For special sealing solutions, a

component store containing 350 diff erent semi-fi n-

ished articles in varying dimensions and materials

can be called upon.

HKO tests each cylinder on a semi-automatic test

rig. The cylinder can be checked in any piston posi-

tion, thereby off ering even greater security for the

customer.

As a safeguard to ensure the established

HANSA-FLEX delivery quality is maintained, HKO

conducts detailed incoming goods inspections as

part of its routines as a DIN EN ISO 9001 certifi ed

operation. When the hydrauliccomponents are then

delivered to the customer, they are immediately

ready for installation.

HYDRAULICCOMPONENTS

13

Hydraulikpresse talked to Tino Zeuner (Dipl-Ing.),

head of the Hydraulic Components division of

HANSA-FLEX Hydraulik GmbH.

: How do you ensure

the branch staff are appropriately qualifi ed to

sell the component range in a convincing man-

ner?

Tino Zeuner: Our hydraulic component specialists

provide technical support and advice, including

in person at the branches. Of course, we provide

staff with an introduction to the bilingual cata-

logues, teach them about technical specifi cations

and the technical background, so that they are

able to ask customers the right questions. On our

Intranet they can fi nd structured enquiry forms

and comprehensive product information, which

we regularly update. Our product range is likewise

adapted constantly to requirements.

We also work closely with the external advisors of

the various groups. They support the branches in

selling the specialist products.

: What benefi t does

this hydraulic component know-how bring to

HANSA-FLEX branch staff ?

Tino Zeuner: More satisfi ed customers! Customers

who increasingly expect to obtain their solutions

all from one source, and who utilize HANSA-FLEX

as an expert system supplier and partner.

INTERNATIONAL

HANSA-FLEX FranceLike a phoenix from the ashes

Our colleagues at HANSA-FLEX in France had a tough

time of it after a fi re destroyed one of their branches.

Eric Zarb was appointed to head HANSA-FLEX France

following a management restructuring in October

2005, and since that time all the staff have put in a

sterling eff ort to turn the company into a byword for

hydraulic services in France.

But let’s go back to the beginnings: In May 2000 the

fi rst HANSA-FLEX branch in France was established

near the town of Gardanne, in the south of the coun-

try, in the last of its surviving coalfi elds. The coal-

fi eld was fi nally shut down in 2004, but well before

then – in 2002 in fact – the branch had relocated to

Gemenos, an area marked by a strong shipbuilding

industry and so off ering major customer potential.

Progress was rapid over the following years, and

the French operation steadily built up its

branch network. The

branch in Ostwald was opened in the same year,

2002. From there – close to Strasbourg in eastern

France – the staff cover an extensive territory in-

corporating both an industrial and an agricultural

customer base. In March 2003 came the branch in

Woippy near Metz, and then in January 2005 – the

last new opening to date – the Petite Forêt branch

near Valenciennes was established.

The motto of our colleagues in France is: “There are

no problems, merely solutions to be found”. In line

with that approach, they are wholeheartedly com-

mitted to ensuring their customers‘ satisfaction and

to solving their hydraulics-related problems. Five

FLEXXPRESS service vans operate in France. The fi rst

three were launched as far back as 2003, with two

new ones being added last year – one stationed

in the south of the country and

another linked to the

Ostwald branch. The deployment of all FLEXXPRESS

vans is closely linked to the branches. They all help

each other, in line with the famous Musketeers’

motto: “All for one and one for all”. Only when the

vans’ capacity has been fully utilized by the local

branch is the FLEXXPRESS deployment schedule

handed over to a special centralized control. That is

to say, the vans‘ deployment is fi rst coordinated by

the branches, so as to provide a joint approach in

meeting customers’ needs.

Great attention is paid to staff training. All staff are

focussed on marketing the company’s potential as

a hydraulics full system vendor even more success-

fully in the future. The company’s customer base in

France includes major international corporations

such as Liebherr, the world’s largest manufacturer

of geotechnical equipment; Solétanche; and the

steel pipe manufacturer Case Vallourec. But wheth-

er in its OEM or parts business, in France as else-

where HANSA-FLEX is committed to close attention

to its customers’ needs: It was there, in 2003, that

for the fi rst time a fully equipped service workshop

container was deployed on a building site near

Marseilles. In 2006 the French network of branches

was supplemented by the fi rst HANSA-FLEX

shop, near Vitrolles.

ISSUE FEBRUARY 200714

HYDRAULIKPRESSE 15ISSUE FEBRUARY 2007

“It’s never been as much fun as it is at present.” Reiner

Plöger, manager of the HANSA-FLEX branch in Oyten,

talks about the expanded industrial service opera-

tions.

The branch only moved to Oyten as recently as

2003, having previously been housed in the same

Bremen building as the HANSA-FLEX head offi ce.

Now it’s right by the motorway. Any customers in

urgent need of a replacement part can reach Oyten

without getting stuck in jams. And they like com-

ing. The over-the-counter business is very impor-

tant to a branch operation.

However, the trend – as Reiner Plöger has found

– is moving towards full service, including instal-

lation. Customers are more often expecting to have

their parts installed. That was the case recently,

when HANSA-FLEX Oyten was contracted to replace

200 hose lines at the Bregal 1 sheet galvanizing

plant of Bremer Galvansierungs GmbH in Bremen.

Full installation, within a tight time window, was

part of the contract.

First the specifi cations were identifi ed and the

installation team assembled. The branch-linked

FLEXXPRESS service van 701 served as the base sta-

tion. All newly installed hoses were provided with

X-CODE coding; in fact, the customer had decided

to employ X-CODEplus as a further enhancement in

terms of error prevention and ease of re-ordering.

Reiner Plöger discovered just how happy the Bregal

1 shift managers were with the Oyten team when

he was greeted on a visit there by the words “That‘s

a great crew you‘ve got there!”. The “crew” not only

includes staff from the Oyten branch, but also from

the group branches in Arsten, Bremerhaven and

Bremen-North, the FLEXXPRESS van drivers and

staff at the Oldenburg industrial installations cen-

tre. The second order, for the Bregal 2 galvanizing

plant, quickly followed.

In contact with the product

The contract awarded by Sloman Neptun Schiff -

fahrts AG, based at the Lloyd shipyard in Bremer-

haven, also specifi ed installation included, and

the fi tters were booked straight away. All the hose

lines on the cranes, winches and other hydraulic

systems of the gas tanker “KAPPAGAS” were to be

replaced. In order to meet the tight deadline, fi ve

men worked on the tanker.

Installation was also part of the package when

the Oyten branch recently carried out a job for the

Bremen Institute of Materials Testing. In order to

meet the organization’s high safety standards, all

the hose lines on its testing equipment – presses

and set-ups for testing cracking, tensile strength

and vibration – were replaced. In all these con-

tracts Reiner Plöger observed something new: an

additional boost to his staff ’s motivation. The in-

creasing numbers of installation contracts require

teams to be formed, according to the scale of the

job. “This involves deploying technicians who

previously worked only in the workshop. They are

now coming into contact with the customer’s end-

product, and they like it a lot”, the branch manager

reports. He places great value in ensuring that all

his staff operate on the same basis of know-how, so

each of them attends a training course twice a year.

“Our people are proud and highly motivated.” That

is why Reiner Plöger also has no problems when he

occasionally needs staff to work night shifts.

Reiner Plöger also considers HANSA-FLEX’s progres-

sion to becoming a system vendor to be a positive

development, which has in his view been a great

success. Oyten utilizes the specialist departments

to provide its customers with the necessary level

of satisfaction. Close ties have been formed with

the sealing specialists in Eisenberg, as well as with

the special fi ttings and pipes department and all

the other HANSA-FLEX specialist centres of com-

petence. That might well also spell good news for

Bregal, because Reiner Plöger has put together a

working party made up of staff from the special-

ist departments to present to the customer the

whole range of HANSA-FLEX products and services.

“It means a solution can be found quickly and ef-

fi ciently. After all, our focus is always on providing

our customers with rapid assistance.” At the Oyten

branch it works a treat!

On-the-job motivationChanges at the workplace

GERMANY


It’s fi ve o’clock in the morning in Berlin. It‘s still dark

when two FLEXXPRESS installation teams and the

cylinder repair specialists from Königshofen arrive at

the Berlin branch of Borgers. They are there to carry

out a routine cylinder repair. Johann Borgers Berlin

GmbH & Co. KG is a textile company which supplies

the automotive industry. Founded 15 years ago in

Berlin, the company is part of the Borgers Group, a

family business with a history stretching back more

than 140 years. It makes insulation components and

soundproofi ng, carpeting for cars, parcel shelves and

roofl iners.

On this morning, the HANSA-FLEX installation

teams are actively assisting their colleagues

at Borgers in replacing the hydraulic cylinders

– components which are at the heart of the giant

thermo-presses used in production. The presses

manufactured by the Olbrich engineering com-

pany (another member of the Borgers Group) to

form the mouldings run continuously in three-shift

operation. At a processing temperature of 170 to

200 degrees Celsius, insulating and soundproofi ng

mats made of felt or wool and resin are formed in

the press moulds at operating pressures of around

240 bar, peaking at up to 300 bar. In order to build

up the necessary pressure, the moulds are pressed

together by four mighty hydraulic cylinders, which

are subjected to enormous loading in the process.

Continuous strain, high operating temperatures

and high pressures cause wear. That is why the

maintenance team headed by Thomas Stoll takes

particular care in servicing the presses, including

regular inspection of the cylinder.

That is what is happening this morning. First all the

hose lines are dismantled and the cylinder open-

ings carefully sealed off . The crane is in position at

the agreed location punctually to the minute. Now

the roof of the production hall is lifted and the 1.5

tonne cylinder is carefully and safely manoeuvred

out of the thermo-press. Then the identical-design

replacement cylinder is installed and very quickly

the machine is back running at maximum load

capacity.

Assembly lines can’t wait

It is important that everything should run smooth-

ly, because the automotive component supplier can

aff ord no delays to its production. Borgers supplies

textile components which play a key role in insulat-

ing and soundproofi ng motor vehicles, as well as

trim components for vehicle interiors. There is a bit

of Borgers in every make of car. Of course, keeping

to delivery deadlines is an absolute must, because

shipments are sent directly to the assembly lines of

all major carmakers as part of the just-in-time sys-

tem. In order to safeguard its production, the Borg-

ers maintenance department undertakes active

measures to avoid unscheduled machine down-

times, including holding stocks of key replacement

parts. And one of those is the replacement cylinder

now ensuring that the thermo-presses can con-

tinue operating.

The removed cylinder is now on the way to the

state-of-the-art HANSA-FLEX cylinder repair centre

in Königshofen, where the company’s specialists

will immediately subject it to an initial analysis.

That appraisal fi nds that the hose connections need

to be replaced; the piston rod is polished and the

cylinder re-honed and re-sealed with perfect-fi t-

ting gaskets. The Viton sealing material used is

specially tailored to the strains imposed by the high

operating temperatures. A short time later the cyl-

inder is ready to go back into service.

Repair in record time

This absolute reliability is of special value to Tho-

mas Stoll. “We don’t want them to perform magic”,

say the head of the Borgers maintenance depart-

ment, “the key factor is that agreements are clearly

set out and are adhered to unconditionally. And of

course in exceptional situations we also look for

that bit of extra commitment.” That’s no problem

for Jens Kalesse, sales manager of the cylinder re-

pair department in Königshofen, and all deadlines

to date have been safely met. That is one of the rea-

sons why Borgers has such faith in the commitment

of the HANSA-FLEX cylinder repair team. And that

faith was strengthened even further recently when

a machine breakdown occurred.

Two cylinders went down at the same time, pos-

ing a major challenge to the team under workshop

manager Mike Sittig in Königshofen. In a situation

such as that the customer benefi ted from its long-

standing partnership with HANSA-FLEX, because it

meant that all the cylinder specifi cations were held

on fi le in Königshofen. Preparations to remedy the

situation could begin straight away. While the de-

fective cylinders were still being removed in Berlin,

HANSA-FLEX was already turning the new piston

rods so that they could be immediately joined to

the cylinders. It was a repair carried out in record

time.

Out through the roof“That bit of extra commitment”

CYLINDER REPAIR

No wonder Borgers has been relying

on HANSA-FLEX, not only for cylinder

repairs but for everything hydraulics-re-

lated, since 2001. The customer is closely

supported by Harry Parnitzki from the

HANSA-FLEX branch in the Marzahn dis-

trict of Berlin, from where he coordinates

all the hydraulic servicing operations

needed. All hydraulic hoses installed

at Borgers are coded with the X-CODE

system, aiding the rapid re-ordering of

replacement parts. Borgers enjoys the

benefi ts of that system, as it does

the facility to qualify its staff at

HANSA-FLEX. They regularly at-

tend courses on pipe and hose line

engineering at the HANSA-FLEX training

centre in Weixdorf near Dresden. Borgers is

particularly keen on the special training rigs

HANSA-FLEX has set up there. In fact, the customer

liked them so much that it decided to purchase one

of its own to provide in-house training for its me-

chatronics apprentices, to familiarize them with the

variety of hydraulic operations needed.

The Borgers maintenance staff routinely check all

the thermo-presses in order to eliminate the pos-

sibility of any delay to production, to safeguard

product quality and to avoid costly reworking or

even recalls. After all, in view of the high operating

temperatures and pressures at work even a minor

oil leak would pose a safety risk to personnel and

the environment. Consequently, oil leaks must be

avoided, so as to eliminate any operational risk.

This imposes a particular responsibility on the serv-

ice operation. And the routine cylinder repair itself

being carried out this morning in Berlin is complex

and challenging enough. But with the support of

FLEXXPRESS and the HANSA-FLEX cylinder repair

team it is once again completed smoothly and ef-

fi ciently.

HANSA-FLEX hydraulic cylinder repairs

Quality in any event

Generic repair

of all cylinder types

Component repair or replacement

Honing of cylinder pipes

in 25 - 500 mm diameter

Boring, cylindrical surface grinding

and chroming

Gaskets from 5 - 535 mm

The Königshofen specialists off er a full

service package all from one source.

For the customer that means:

Full cost transperency

Minimal downtimes

No stock-holding costs

CYLINDER REPAIR


The staff from the HANSA-FLEX group headed by the

Albrecht brothers have collected donations to aid the

work of the SOS Children’s Villages charity in Zimba-

bwe. They collected a total of 1,000 Euro, which was

generously topped up with a further 3,700 Euro by

Thilo and Jürgen Albrecht. A tidy sum to help the AIDS

orphans of Zimbabwe.

One of those who will benefi t from the donations

by the HANSA-FLEX staff is six-year-old Nyasha,

who lost both her parents to AIDS and now, along

with her four brothers and sisters, is being brought

up solely by her 14-year-old sister Yumna. Some

6,000 people a week die of the terrible AIDS virus

in Zimbabwe. Out in the countryside, in particular,

the epidemic often has catastrophic consequences.

When parents die, children have to look after their

younger siblings. Fortunately for some of the chil-

dren, there are people like Miss Thandeka. The

social worker is based at the SOS welfare centre

in Bindura, providing support and assistance to a

number of children and their families in the area.

Nyasha and her brothers and sisters are also in her

care, and she makes sure they are regularly able to

collect their food parcels from the SOS centre.

The SOS welfare centres help with short-term aid

such as monthly food parcels, paying school fees or

providing school uniforms. In the longer term, the

staff at the centres see their role – in conjunction

with the state and local authorities – in building up

a social welfare network for the needy, especially

the orphaned and abandoned children. The SOS

welfare centres have also got together with the

International Labour Organization (ILO) to provide

many families with the know-how they need to set

up small businesses and so generate an income for

themselves. For six-year-old Nyasha the priority is

that she should attend the local primary school. Her

younger brother is happy to be able to attend the

playgroup at the welfare centre three times a week.

Nyasha and some 1,200 other children and their

families in Bindura have found hope once again,

and are facing the future with courage.

Bindura was the site of the fi rst SOS Children’s Vil-

lage in Zimbabwe established in 1980. There are

now three SOS Children’s Villages in Zimbabwe,

three youth clubs, three kindergarten centres, fi ve

SOS Hermann Gmeiner schools, four job training

centres and three SOS welfare centres. One of them

is the centre in Bindura, which primarily provides

a welfare programme to socially at-risk families

and children whose parents have died of AIDS. The

aid ranges from material support, through psycho-

logical counselling, to boosting the people’s own

life skills. In early 2002 SOS Zimbabwe actively

responded to the spreading epidemic by establish-

ing AIDS welfare programmes to support families

and children within their own environment. Life

expectancy in the crisis-ridden nation in southern

Africa is just 33 years. Out of every 1,000 children,

129 die before their fi fth birthday.

The 4,700 Euro donated by the staff of the

HANSA-FLEX Albrecht group will help ensure the

AIDS orphans of Zimbabwe are not abandoned and

end up on the streets, but receive healthcare and

legal advice, as well as the essential help to help

themselves.

HANSA-FLEX donates to SOS Children’s VillagesHelp for orphans in Zimbabwe

NEWS


HYDRAULIKPRESSE

A defective, oil-soaked hose does not belong in a

landfi ll pit, but should be disposed of properly in line

with environmental regulations. Improper handling

is frequently seen to occur. That is why HANSA-FLEX

has for some time now, at a small charge, been of-

fering its customers a disposal facility for used hoses.

This represents an environmentally friendly approach

as laid down in the DIN EN 14001 environmental

standard. The standard sets out what companies

must do in all matters relating to environmental

protection.

Manufacturing and service companies are expected

to act in an environmentally aware manner, includ-

ing the operation of a specifi c environmental man-

agement system. After all, the operations of every

business impact upon the environment to a greater

or lesser extent and all – including those with no

certifi cation – must comply with environmental

laws, regulations and standards. Certifi cation to the

DIN EN 14001 environmental standard helps struc-

ture and initiate processes within the company, so

bringing both ecological and economic benefi ts.

The 14001 standard is enjoying increasingly wide-

spread acceptance and recognition, according to

Thomas Schilling (Dipl. Ing.), senior auditor with

the certifi cation body Germanischer Lloyd (GL).

One of the key reasons is that it establishes legal

certainty in the handling of emissions and hazard-

ous materials, and with regard to waste disposal.

And: “Standard 14001 is also playing an ever more

important role in supplier assessment in the auto-

motive industry for example.” Thomas Schilling has

found that “it can

quite possibly have a positive infl uence on a de-

cision where quality and price are equal.” Jörg

Hartmann, responsible for quality management

at HANSA-FLEX, asserts that the company already

operates in an environmentally friendly manner in

everything it does. Nevertheless, the processes in-

stigated by the environmental certifi cation system

are of interest to the Group, which is why prepa-

rations are under way for certifi cation to DIN EN

14001 at a later date.

Focus on each individual branch

Jörg Hartmann sees many advantages for the

company in addressing the requirements of the

standard at such an early stage. “The argument

that 14001 just costs money is a prejudice”, Thomas

Schilling affi rms, continuing: “14001 is without

doubt a key instrument by which environmental is-

sues can be addressed in a structured way. It quickly

opens up substantial economic potential, which is

also of major benefi t to the environment.”

In studying the standard and preparing for certifi -

cation it is necessary to focus intensively on each

individual branch, analyzing its environmental

practices and methods of working, and taking the

opportunity also to view what goes on from a dif-

ferent angle. Key areas of focus include the use of

resources, the design of workplaces and compliance

with waste disposal legislation.

Environmentally friendly at every workplace

Cleanliness and tidiness at the workplace is also

boosted by the introduction of DIN EN 14001, there-

by helping to promote quality of workmanship

and responsible treatment of the environment. In

order to largely eliminate waste, HANSA-FLEX will

in future consult its suppliers to determine what

additional possibilities exist for reducing the use

of packaging material without impacting on the

quality of the packed component. And GL auditor

Schilling makes another point worth considering:

“DIN EN 14001 also promotes awareness of the

need to establish alarm systems and emergency

response procedures. That is to say, how well pre-

pared a company is to deal with an environmental

incident. Rapid response is particularly vital where

the incident might contaminate the ground-water

in a drinking water area for example; something

like that can get very expensive.”

Already environmentally friendly

The management of HANSA-FLEX Hydraulik GmbH

has recognized the potential benefi ts of the 14001

standard to the processes and procedures within

the HANSA-FLEX Group. “Although our current cus-

tomer base structure does not yet necessitate cer-

tifi cation to DIN EN 14001 as an essential step, we

will in future be supplementing our internal audit

procedures in line with the requirements of the DIN

EN 9001:2000 standard to incorporate aspects aris-

ing from 14001”, states Jörg Hartmann.

DIN EN 14001 – More environmental protection and improved profi tability

What will the standard really deliver?

ENVIRONMENTAL PROTECTION



Human beings have always generated waste, yet

systematic disposal of it began only around a hun-

dred years ago. Now we have long passed the stage

of merely disposing of waste. What was in earlier

times simply thrown away is today seen as a valu-

able resource for the future. Actually recycling has

always been practiced, it merely went under a dif-

ferent name. In the olden days we had rag-and-bone

men and scrap metal dealers for example. Nowadays

an entire industry is concerned with managing and

processing waste and its effi cient recycling.

To ensure waste is recycled effi ciently, it needs to

be separated appropriately. The technologies de-

ployed in sorting and reusing waste are becoming

ever more effi cient. A key role in resource recovery

is played by systems which are able to rationalize

the selection process, sorting entire mountains of

waste into the appropriate material categories.

A specialist in such systems and equipment is

HAMMEL Recyclingtechnik GmbH, which manufac-

tures a wide range of high-performance treatment

plants and robust single machines to handle the

tasks involved. Its products extend from a power-

ful primary crusher, to secondary crushers, sieves

and sorters, through to high-end stationary com-

bination systems. The company’s origins were in a

machine-fi tting business, and the invention of the

so-called HAMMEL ‘two-shaft principle’, a tech-

nique which underlies all present-day shredders

and crushers.

With a worldwide workforce of 500 people, the

company based in Bad Salzungen, between Ei-

senach and Bad Hersfeld, is a leader in crushing

technology. With its subsidiaries and global sales

and service network, HAMMEL handles a wide va-

riety of recycling tasks.

As one example, HAMMEL equipment helped sort

waste, including bulky items and construction rub-

ble, in New Orleans in the aftermath of Hurricane

Katrina, deploying primary and secondary crushers

to assist clearing operations.

A quick call round the corner

Since the year 2000 HAMMEL and HANSA-FLEX

have built up a very close relationship in the hy-

draulics fi eld, initially served from the Niederaula

branch. In order to provide the customer with even

closer support, in June 2006 HANSA-FLEX opened a

new branch in Merkers – just round the corner, so

to speak. Now a member of HANSA-FLEX staff can

be at the HAMMEL site within ten minutes when

needed. Branch manager Achim Wolf coordinates

the relationship in its entirety from his Merkers

base, ensuring HAMMEL receives everything it

needs all from one source. That includes hydraulic

components from the warehouse in Weixdorf near

Dresden, where special aluminium blocks housing

the complete multi-way valve set-up, produced to

customer specifi cation, are also held in stock.

The Merkers branch itself produces all hoses in

sizes from N6 to N40 and holds them in stock, be-

cause HAMMEL expects rapid-response delivery

direct to the assembly lines – including overnight.

HANSA-FLEX receives from the customer complete

hose lists which may contain between 135 and 350

individual items.

Hose lines are primarily used on the recycling sys-

tems because the equipment is highly compact in

design and so there is little space for the hydraulic

connecting elements. Hoses not only take up the

least space, they also off er the necessary fl exibility

to damp the occurring vibration.

The machine designers are experts in hydraulic sys-

tems, but are also happy to call upon the extensive

technical know-how of Achim Wolf – who calls on

his customer on a daily basis – in order to further

optimize solutions. Examples include the use of

screwed couplings, or when quick modifi cations are

needed to hydraulic components on a recycling ma-

chine built to special customer specifi cation.

Recycling down to perfectionHAMMEL masters its mountains of waste

RECYCLING

Rapid assistance withlittle baggage

When it comes to repair needs, too, HAMMEL re-

lies on the expertise and service availability of

HANSA-FLEX. Because when assistance is needed,

it’s needed fast. Unscheduled downtimes of waste

processing plants simply cannot be tolerated, be-

cause waste trucks are arriving every minute, and

their drivers work to very tight

schedules. They can’t aff ord to be stuck in jams at

the waste depot. The general public expect their

rubbish to be collect punctually. That is why HAM-

MEL purchasing manager Romy Schlotzhauer plac-

es her trust in HANSA-FLEX as the partner of choice

when it comes to hydraulic repairs.

“I know I can rely on them 100

percent.”

The closely networked linking between all the

HANSA-FLEX branches has been a particular boon to

the partnership. Though HAMMEL operates its own

teams of service technicians covering the long-life

equipment, they do not always have hydraulic parts

on-board. In such cases HAMMEL can call upon the

close-knit network of HANSA-FLEX branches, with

their rapid parts availability. “We have clearly

agreed prices with HANSA-FLEX, which apply at

every location,” says Romy Schlotzhauer. “That

helps our buying process, because we don’t have

to worry about spending time getting alternative

quotes, which would waste valuable time which

we often do not have when repairs are needed.”

HAMMEL is logged as a customer in the HANSA-FLEX

system database, so the manufacturer’s technician

merely needs to identify the need for a replace-

ment on the defective machine, locate the nearest

HANSA-FLEX hydraulics service centre by postcode,

and go to the branch to collect the required article,

quoting the relevant customer number and taking

away the delivery note for his records. “It repre-

sents time gained which benefi ts us in terms of the

quality of service delivered to our customers”, says

Romy Schlotzhauer. One of the side-eff ects of this

in-person procurement system is that only “fresh”

new hoses are installed, meaning the full six-year

service life can be utilized.

RECYCLING


SHAREHOLDERS‘ MEETING

22

SHAREHOLDERS‘ MEETING

23


“And then the customer’s in the branch wanting

advice about some hose or other.” It’s a situation

HANSA-FLEX staff know all too well. “We are the ex-

perts, so understandably customers turn to us with all

kinds of hoses, and expect us to help”, reports Carsten

Kempfert. He explains the best way to respond.

Carsten Kempfert holds seminars at the

HANSA-FLEX training centre on prevention in pipe

and hose line engineering, aimed at teaching staff

the many aspects of safety in relation to people and

the environment. He has a fi rm rule when custom-

ers are asking for information about unspecifi ed

hoses: “Never say anything unconsidered, and never

give out unsupported information!” Because a hose

is not just a hose; each one has a diff erent specifi -

cation, a diff erent performance spectrum. After all,

hoses fulfi l extremely varying needs. Hoses which

may look very similar can react completely diff er-

ently when coming into contact with a certain me-

dium or when subjected to pressure. So it is crucial

to obtain accurate information. “From standards or

manufacturers’ data sheets for example. The mark-

ings on the hose also give detailed information. If

all that fails to deliver suffi cient detail about the

hose, all staff are able to call the Technical Depart-

ment at the HANSA-FLEX head offi ce.”

Only when sound information has been obtained

should it be given out. Both trainers and the col-

leagues from the Technical Department warn

against making unconsidered statements: “It is

best to provide information only in writing, because

the range of hoses is simply too diverse”. Industrial

hoses alone extend over a wide variety of types:

diff erent demands are placed on an unmanned

sewer-fl ushing hose than on a drinking water or

fi re-fi ghting hose. It must be fl exible enough to get

round bends in the sewer, but at the same time it is

subject to massive abrasion.

The question of whether acid or alkali material is

being carried is also of importance to chemicals

hoses. This demands clear knowledge of what can

impact on the polymer. And then staff should also

know whether it is advisable to recommend cus-

tomers an alternative made of PTFE material or a

metal hose.

Sound knowledge helps

So it is well worthwhile focussing on prevention

with regard to the use of hoses. “Especially when

we are assisting hydraulics customers with safety-

related components.” That applies particularly to

metal and PTFE hoses, of which the special proper-

ties are ideally suited to transporting acids, alkalis,

gas, fl uid and solids – whether hot or cold. These

hoses within the HANSA-FLEX product range are

frequently deployed where hazards to people and

the environment must be avoided at all costs. Such

as when carrying boiling hot sulphuric acid. That is

why the metal hoses are tested comprehensively

with regard to leak-tightness, cleanliness, perfect

weld seams and burst response.

Responsibility for the design and production of

the hoses is placed exclusively in the hands of the

specialists at HANSA-FLEX Metal Hoses in Boff zen.

They know precisely what properties such a hose

needs to have, and how it is installed. Great care

needs to be taken even prior to installation: What

is there in the immediate vicinity of the hoses? Are

there system oscillations or vibrations which might

pose a safety risk?

Hydraulic hoses – points to note!

A hydraulic hose, in all its special design embodi-

ments, demands no less care and attention to de-

tail. Firstly the material selection is key of course.

What fl uid is to be transported: water, water-oil

emulsions, mineral oil or biogenic hydraulic fl uid?

What pressures will be applied, what temperatures

will prevail, and how must the fl ow rate be meas-

ured? All these questions need to be answered prior

to installation.

Where can staff fi nd the required information? As

a general rule, hydraulic hoses are marked by the

manufacturer. As an example: the HD 400 hose

used by HANSA-FLEX corresponds to standard des-

ignation 4SP, for which all the technical specifi ca-

tions are set out in DIN Booklet 174. This is useful

information when it comes to making the right

decisions. As HANSA-FLEX supplies many OEMs, it

must be ensured that goods are shipped only as

specifi ed in consultation with the customer. “We

cannot simply make modifi cations of our own,

because of delivery bottlenecks maybe”, explains

Carsten Kempfert. “In such cases an alternative has

to be specifi ed together with the customer.”

Prevention starts early Give out only factual information

TRAINING CENTRE

max. 2 years.length of timein storing

max. 4 years.Age of hoses

max. 6 year. sLength of time in using hose line

A B

A = Production date of hoses B = Production date of hose line

HYDRAULIKPRESSE

The service lives of hydraulic hoses and hose line are

key to aspects of prevention and safety. In the event

of a breakdown, exceeded service lives can have a

serious impact on plant operators, including loss of

insurance cover or allegations of gross negligence,

with all the legal consequences. Experience shows

that judges in court cases will demand to see main-

tenance documentation in order to assess how the

operator has fulfi lled its duty of care.

Marriage after four years

In view of those considerations, the following rules

must be followed: Hydraulic hoses must be stored

for no more than four years, counted from their

date of production. They must then be ‚married’ to

the fi tting! If it is then installed in a hydraulic sys-

tem, its service life should come to an end after six

years (including the potential storage time of two

years). Experience has shown that the ageing proc-

ess leaves its mark even under optimum operating

conditions; the elastomers change, harden, crack

and become brittle. Similarly, the wire fabric may

also be fatigued after such a period of time by pres-

sure or reversed bending. And on the inside, too,

hardening of the material or bubbling of the elas-

tomer may result, impairing the fl owability of the

fl uid. There may well be reasons for replacing some

hoses after a shorter period of time, or for extend-

ing the six-year service life. But that can only be

judged by an ‚Authorized Person’!

HANSA-FLEX staff know that the safety of people

and the environment is at the focus of any solution,

alongside the availability of machines and systems.

Because: “We are aware of our responsibility”.

TRAINING CENTRE

Authorized Person

What does the term ‚Authorized Person‘ mean?

According to the Health and Safety at Work

Regulation issued by the Employers‘ Liability

Insurance Association (Berufsgenossenschaft), such

a person is one who is “by virtue of their training,

experience and current duties in possession of the

specialist knowledge and skills required to test the

hydraulic hoses and authorized to issue instructions

during testing”. The term ‚current duties‘ indicates

that the person concerned must not only have

experience in conducting the scheduled tests,

but is also familiar with the latest state of the art

regarding the equipment under test and with the

hazards to be investigated.

HANSA-FLEX trains staff as ‚Authorized Persons‘

at its training centre, and they are then accredited

to conduct testing of safe installation and use for

example.

Authorized Persons may only issue binding

declarations on behalf of HANSA-FLEX when so

authorized in writing by the management.

25


Please send your replies by e-mail to info@hansa-fl ex.com, or by mail. Please don’t

forget to include your name and address. Entry deadline is 28th February. One reply

only per participant. Any recourse to legal action and any liability shall be excluded to

the extent permitted by law. The prize may not be paid out in cash.

Quiz

QUIZ | TRAINING SESSIONS | TRADE FAIRS

How many hydraulic components are

available at HKO in Dresden-Weixdorf?

A: 2.500

B: 3.000

C: 3.500

06.02. to 09.02. Umfassendes Grundlagenseminar über die Schlauch- u. Rohrverbindungstechnik in Theorie und Praxis Boff zen

12.02. to 16.02. Grundlagen der Fluidtechnik Teil 1 Weixdorf

19. 02. 2007 Grundlagen der Dichtungstechnik Eisenberg


22. 02. 2007 Grundlagen der Leitungstechnik Bremen


15. 03. 2007 Grundlagen der Leitungstechnik Bremen


02. 04. 2007 Grundlagen der Dichtungstechnik Eisenberg

For further information please contact Mrs. Silvana Wagner (Training center Weixdorf): +49 - 3 51 - 41 39 719.

Training seminar schedule February – March – April in german only

Winner edition 12/06: F. Lehmbeck, Bergedorf

E. Dietrich, Argelsried

D. Müller, Berlin

14.02. to 18.02. VDBUM 2007 Braunlage, Germany 12.03. to 14.03. LifeCom Düsseldorf, Germany

14.03. to 16.03. Zuliefermesse Leipzig Leipzig, Germany 22.03. to 23.03 National Heavy Equipment Show Toronto, Ontario

10.04. to 13.04. Machinery Construction 2007 Chelyabinsk, Russia 16.04. to 20.04. Hannovermesse 2007 Hannover, Germany

23.04. to 29.04. BAUMA Munich, Germany 09.05. to 13.05. Intermach 2007 Bangkok, Thailand

22.05. to 25.05. MSV Nitra, Slovakia 21.06. to 23.06. Tiefbau Live Schwalmtal, Germany

Answer edition 12/06:

B: 2002

Trade fair announcements14.02. to 18.02.

14.03. to 16.03.

10.04. to 13.04.

23.04. to 29.04.

22.05. to 25.05.

Win one iPod Nano (PRODUCT) RED Special Edition!

Simply answer our quiz question and the iPod Nano (PRODUCT) RED

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Topics in the next issue will include...

Copy deadline: March 1, 2007

LITERATURE | FIGURES & FACTS | PREVIEW

Preview

27

PEDAX/STEMA Enhanced service options based on OEM contract

JaNo Maschinenbau A deep-founded partnership

HANSA-FLEX training centre News on Employers‘ Liability Insurance Association rule 237

Industrial installations Replacement of 130 hoses in record time

Barthelwerft shipyard Mobile pipe-bending service

Arzberg coal-fi red power station Hydraulic workshops safeguard high work tempo

04/07

Schulungsbuch “Fluidtechnik“ | 25,00 EUR **

by Wolf-Rüdiger Schmidt, Helmut Wetteborn, Ulrich Hielscher

2nd edition | 292 p. | internal publication: HANSA-FLEX

DIN-Taschenbuch 174 | approx. 90,50 EUR *

Schlauchleitungen für die Fluidtechnik

4th edition | 472 p. | Published by: Beuth | ISBN: 3410145451

Die Bibliothek der Technik,Präzisionsstahlrohre | approx. 8,60 EUR *

by Barbara Wantzen

70 p. | Published by: Moderne Industrie | ISBN: 3478932130

Hydraulik | 59,95 EUR ***

by Dieter Will, Norbert Gebhardt, Hubert Ströhl

2nd Edition | 373 p. | Published by: Springer | ISBN: 3540343229

** Training manual is available at your nearest HANSA-FLEX branch

Recommended reading

Figures & Facts

163

66

HANSA-FLEX Hydraulik GmbH Würzburger Str. 1c 97753 Karlstadt am Main Germany

HANSA-FLEX Hydraulik GmbH Hansastr. 92 49134 Wallenhorst-Hollage Germany

Hansa Flex spol. s r.o. Nejdecká 814 357 35 Chodov Czech Republik

HANSA-FLEX AG Marschalkenstraße 10 4132 Muttenz Switzerland

GermanyTotal

289

118

Openingssince January 2007

30 years: HANSA-FLEX Hamburg Stellingen

20 years: HANSA-FLEX Langenhagen | HANSA-FLEX Paderborn | HANSA-FLEX WittlichAnniversaryJanuary 2007

*** Book is available at HANSA-FLEX Training Centre * Books are available in all bookshops

Wir kennen unsere Verantwortung.

It‘s not a trick – it‘s a system !

HANSA-FLEX Hydraulik GmbH

Zum Panrepel 44 · 28307 Bremen · Germany

www.hansa-fl ex.com · info@hansa-fl ex.com

Documents

02/07 Nominal Charge 2,00 EUR HYDRAULIK - … ISSUE FEBRUARY 2007 The managing directors Uwe Buschmann Thomas Armerding Dear reader, HANSA-FLEX has had a successful year. That claim