Material preparation
The processes we carry out at our plant allow us to fully prepare the material in any way that is required, within the scope of the technologies used.
Etching: process during which the layer of oxides is removed from the wire rod surface and the latter is cleaned. Additionally, a bonder can be applied during this process, producing a sub-grease layer facilitating plastic forming. The related tasks are carried out using an Ekomor automated line to assure bath parameter stability.
Annealing: process which includes spheroidize annealing, whose aim is to modify the mechanical properties of the wire in a controlled manner. This task is performed by an EBNER line which ensures stable and repeatable parameters thanks to cutting-edge software.
The availability of the processes described above gives us significant flexibility in terms of technology selection, as well as complete supervision of material preparation.
Broaching: a process that allows us to obtain a final diameter of the material within the range of 3 to 25 mm.
Manufacturing process
Our products are manufactured using the cold forging technology.
This process is carried out at our company using state-of-the-art 5-station forming machines, allowing us to obtain at the same time the shape, the tip, and the thread.
The forging technology is developed by our R&D department, supported by a group of labs relying on computer simulations. Our in-house tool shop allows us to build prototypes of tools, and consequently to reduce product development time.
We manufacture the following two types of products:
Products sized M5 to M14, manufactured mainly for automotive customers using state-of-the-art SACMA SP18, SP28, SP38, and NEDSCHROEF NB515 forming machines. They offer high forging speeds: from 350 to 150 pieces per minute (the forging speed depends on size and head shape).
Products in sizes above M16 are manufactured for the construction, machinery and other markets, using NEDSCHROEF BV5, NB518, NB522, and National forming machines. Machines of this kind are characterised by a smaller forming efficiency, but this is inevitable due to the substantial force required to deform the material plastically: approx. 3,000 kN.
Once formed, the products can be further improved for instance using the following processing methods:
- Washer rolling performed on Ingramatic machines
- Additional machining: turning, milling, drilling.
Heat treatment
We carry out heat treatment at our plant using cutting-edge CAN-ENG equipment.
Each heat treatment line has an automatic process control system, which makes it possible:
to monitor and to regulate the process parameters (temperature, time, carbon potential),
to store the process parameters for each manufacturing order in an archive.
The control system described above and the furnace design (they are fitted, for instance, with integrated washers for phosphate removal) make it possible to carry out the manufacturing process in accordance with the most stringent requirements of the CQI-9 specification.
As the output from the process, we obtain products that may be subjected to further processing, i.e. surface treatment, or dark products covered with emulsion that provides long-lasting corrosion resistance.
Surface treatment
We offer an extensive range of surface treatment options for our products.
We provide a wide array of coatings, meeting the requirements of a various standards. We have two automatic lines for alkaline zinc plating.
Anocote Polska Sp. z o.o., a company implementing state-of-the-art solutions with regard to functional anticorrosion coatings and pre-applied coatings, also operates on the premises of our plant. The company’s services include: zinc flake plating, DÖRKEN MKS®, NOF METAL COATINGS GROUP, and MAGNI™ systems, pre-applied coatings: OmniTECHNIK/precote® and HENKEL/Loctite® (Dri-Loc, Dri-Seal).
As far as other types of ZnNi and HDG coatings are concerned, we use only the services of selected collaborators we have verified.
Apart from coating application, we also offer the option of adding adhesives, sealants, etc. to our products.
Sorting
We offer optical sorting of the products. This allows us to reduce any potential risk of faulty products in the manufacturing batch.
The process is carried out using machines for automatic quality inspection. The fundamental advantages of the automatic optical selection system include in particular:
– contactless measurement and detection of product defects using computer image analysis within a spectrum wider than that perceptible to the human eye,
– high degree of repeatability and reliability of the inspection process,
– possibility of achieving high inspection efficacy and efficiency.
Packaging
We have an automated packaging system in place (with regard to the smaller diameters).
This system allows us to place the products very efficiently in dedicated packaging (cardboard boxes, KLT containers, VCI bags, etc.), as well as to use custom labels.
Logistics
Warehouse – picking – shipment
The KŁFŚ warehouse with a surface area of 3,362 sq m is equipped with high-storage racks, with 7,869 pallet spaces, serviced by 4 Jungheinrich system trucks.
Picking is one of the warehouses processes, during which the goods from the customers’ orders are consolidated and packaged in accordance with the ordering party’ requirements.
The warehouse is open on weekdays from 6 a.m. until 10 p.m. Loading and unloading take place using one of the three available ramps, and side loading is also possible. Shipment capacity of the KŁFŚ warehouse: 180 tonnes per day.
