Waldorf Technik GmbH & Co. KG

„We don’t sell equipment, we provide safety

Waldorf Technik – K 2010 – Hall 7A, Stand B02
„We don’t sell equipment, we provide safety

Waldorf Technik GmbH & Co. KG, Engen, Germany, is a specialized provider of auto-mation for injection moulding productions. The company concentrates on safe solu-tions which are highly appreciated by customers in the medical-technical branch. The specialized engineering company has qualified again for the renowned German award “Top 100 – the most innovative middle-class companies”. During K 2010, Waldorf Technik is represented on the Netstal stand D24 in hall 15 and on the Sumitomo De-mag stand D22 in, hall 15, and maintains an information stand at B02 in hall 7A. The Netstal exhibit displays the largest medical-technical plant – with regard to numbers of cavities – ever shown during a K exhibition.

Plastics above all
We provide innovative solutions for the medical-technical branch as well as for the packaging industry, “says Wolfgang Czizegg, CEO of Waldorf Technik. For the medical-technical branch, the company de-signs automation equipment downstream of injection moulding machines producing consumer articles such as contact lenses, laboratory items such as pipettes or receptacles, insulin injection pens or Petri dishes – almost any plastics part which is required in large quantities. “In the packaging industry we have opened new markets, by substituting glass and tin with plastics”, says W. Czizegg.

Record breaker
During K 2010, Waldorf Technik will be represented on three stands, clearly concentrating on medical-technical applications. Netstal stand D24 in hall 15 highlights a record breaking machine with 96 cavi-ties: “This is the largest injection moulding line of its kind ever shown on a K exhibition,” emphasizes Wolfgang Czizegg. The system produces – at very high output – components for a medical-technical product. “The components are subject to highly stable production requirements. This is why no cavity must be shut off or plugged when a problem arises during the injection moulding process”, explains W. Czizegg. All 96 grippers for demoulding the parts are controlled separately to allow flexible reactions in case of problems. Mr. Czizegg says: “After all, if a single cavity is shut-off in the continuous quality control and surveillance procedure, the entire production cell continues its operation to ensure that the mould flow balance is maintained. The robot simply separates out those components which are even-tually blocked.” In fact, the 96 perfect components are not deposited in a single common chute, but they are located in groups in 16 containers. “All perfect components are used, and in the case of a de-fect at a later point in time the affected batches can easily be identified and separated.“ The supplier is always ready for delivery,” reports W. Czizegg. Consistent readiness to supply is a highly important criterion. A diabetes patient, for instance, must be assured that the insulin-pen he or she is used to will always be available. And product quality must be safeguarded permanently. “Validation and readiness to supply are essential to be commercially successful. We take care of this and show on the Netstal stand how safety works in the supply chain,” says W. Czizegg. On the Sumitomo Demag stand D22 in hall 15, visitors will find a modular plant producing pipette tips in a 32-cavity mould. The automation unit can be adapted to 64-cavity production. Demoulding and cavity-oriented deposition of the parts is demonstrated. A camera unit safeguards complete control in this rather open system – and 100% product quality including pipette geometry is high-end priority: “The principle is a fully modular design. No matter which additional functions are required – such as filter attachments, various further quality surveillance checks or the formation of packaging units – these functions can be added or supple-mented according to individual customer specifications,” explains W. Czizegg. In addition to these two exhibits on the Netstal and Sumitomo Demag stands, Waldorf Technik maintains an information stand within the WVIB community in hall 7A, stand B02.

Safety first
“Competitive pressure in the packaging industry is higher than in the medical branch. The companies have to adapt to the filling lines of their customers which often they do not have their own products. And the price pressure is much higher, too,” summarizes W. Czizegg. Waldorf Technik reacts upon the growing demand for even safer, faster and more productive manufacturing processes with innova-tive engineering power. Says Czizegg: “We compete through a high degree of engineering intelligence and strength. We look at the customer’s market in the centre of the project and then we develop ex-actly the plant for the solution of the problem. In most cases, the robots are of modular design and can easily be adapted to the new products. The market is not very innovative and generally chases noth-ing but cycle times. However, it is more important to recognize what customers really need to be suc-cessful, and to react fast upon those demands.” Wolfgang Czizegg emphasizes that suppliers to the medical-technical branch want to buy process safety: “In cooperation with the customer, experts in the medical environment elaborate process and risk analyses and develop a project from there. The risk is assessed, followed by a detailed statement of the individual safety strategy. This is the unique selling proposition for our customers. We simulate risks and ‘sabotage’ production processes in the test field to learn all imponderabilities and consequently to be able to offer the highest possible level of safety.” This is W. Czizegg’s recipe of success: “We don’t sell equipment, we provide safety.”

Three major methods for barrier packagings
Wolfgang Czizegg recognizes a growing trend where plastics solutions substitute glass and tin con-tainers. Actually, three production methods are represented in the market which are trend-setting and where Waldorf Technik is one of the pioneers: “Firstly, it concerns the cup production involving in-mould-labelling where containers are produced in a single injection moulding operation using multi-cavity moulds. “The barrier function is thus contained in the label,” explains W. Czizegg. The second method utilizes the barrier material as a central layer, injecting Polypropylene and EVOH which has gas barrier properties. Czizegg: “No water vapour or oxygen can migrate in or out of the packaging. EVOH has rarely been used in injection moulding due to lack of traceability or test methods.” Mean-while, a special test installation is utilized in the new ‘Check’n Pack’ automation module which visual-ized EVOH. The savings in production and logistics cost of this method are about 40% compared with those of tin-plate ware. The third method involves conventionally injection moulded plastic cups which are coated with a barrier layer. The extremely thin layer which covers the cup has a similar hermetic property as glass does and offers the potential to substitute traditional packing solutions such as glass and tin-plate ware or aluminium cups. In all three methods, Waldorf Technik has meanwhile reached a high degree of specialization and a leading position worldwide.

Success despite the crisis
For years, Waldorf Technik’s development is characterized by growth. Meanwhile, the company em-ploys a staff of 96 specialists and has recently established a subsidiary in the USA. Main markets are central Europe and Scandinavia with remarkable business growth rates in Ireland, the UK, Middle East, and America. New agents were established in England and France. The Engen, Germany, mother company has doubled its production area. The team of experts, predominantly in design, engi-neering and sales, will be reinforced and a new IT system will be installed. In 2008, the company was able to raise its turnover by 30%, and by 16% in the year of the crisis. Looking at 2010, Wolfgang Czizegg is optimistic: “Last year’s development may continue this way. We find ourselves in a fast de-velopment phase, but with a constant view on the long-term stability of our company – equally impor-tant to our customers and our staff.” One expression of the upward trend is the present (and second) qualification for the ‘Top 100’ companies’ award. The award competition across all branches thor-oughly focuses the innovation management of middle-class companies. The most ingenious and as-similation-friendly firms in Germany are identified, distinguished and honoured this way.

Photos: (Thomas Behne)

Text: 8472 characters (incl. spaces), 1307 words

Ref.: 10-66-02, July 2010

Wolfgang Czizegg, CEO
Waldorf Technik GmbH & Co. KG

Company address:
Waldorf Technik GmbH & Co. KG
Richard-Stocker-Str. 12
D-78234 Engen
Tel. +49 (0) 77 33/94 64-0
Fax +49 (0) 77 33/94 64-39