Production Processes

RAW MATERIAL

The types of sheet metals used in our products are:

Cold-Rolled Sheet (DKP Sheet): 6112 DIN EN 10130-99 DC01
Galvanized Sheet: 1311 DIN EN 10142-00 DX51 D+Z
Stainless Steel Sheet: 304 or 316 (1.4301) grade

METAL PROCESSING

Metal processing is carried out using an automatic line called PSBB, known as an unmanned production method. PSBB refers to Punching, Shearing, Stacking, and Bending operations. The combo storage system allows automatic programming and flexible handling of various sheet parts. Sheets are transferred to the Shear Genius punching-shearing unit. After shearing, parts are collected and stacked using an automatic bending unit with a portal robot for subsequent bending and tamping operations. The material flow automatically performs optimal sequencing to transfer parts directly to the bending center. Parts bent by the portal robot are then sent to the painting process.

PAINTING

All DKP and galvanized parts to be painted are first subjected to a cleaning process. Pressurized spray removes oils, and ionization is applied for passivation. Cleaning at +55°C ensures even the most difficult-to-reach areas are treated and phosphate coating is applied. After cleaning and phosphating, excess moisture is removed (drying stage). Parts then enter the paint booth and are coated using robotic electrostatic application. The robot system ensures uniform paint thickness, giving a smooth finish. Painted parts are then baked in the oven at 200°C for 15 minutes. This fully automated, single-line system ensures all parts move along the same axis without human contact, producing a consistent, error-free painting process. After this process, parts achieve 750-hour salt spray resistance.

SEALING

To ensure water and dust tightness, our products use polyurethane liquid-foam gaskets. Operating temperature ranges from -40°C to +100°C. Applied as a liquid, the gasket cures by air absorption. Once cured, it forms a seamless structure that fully protects the product. Additionally, hot-poured gaskets adhere effectively to surfaces. Combined with polyurethane’s inherent durability, these gaskets maintain their structure under temperature fluctuations and remain functional for many years. They are especially effective in continental climates with large day-night temperature differences, in high-heat production areas, and in applications with internal heat-generating devices.

COATING

Parts with multiple holes or special processing that should not be painted are made from DKP sheet and coated with zinc (Cr+3). Producing these parts as galvanized without coating may result in corrosion where cuts or holes disrupt the zinc layer. For this reason, such parts (e.g., mounting brackets) are zinc-coated in our production.

PACKAGING

To prevent damage during transportation and storage: Small products are placed in double-walled cardboard boxes. Large products are wrapped in cardboard rolls, then protected with air bubble nylon against impact and moisture. All large products are shipped on wooden pallets.