Highlights NETZSCH Campus in Waldkraiburg: Production, Assembly & Logistics Centre

A fundamental reassessment and lean optimisation of all existing processes was done as part of the plant merger. This strategic approach aimed to increase efficiency in production and assembly by minimising waste, improving the flow of materials and optimising production processes. The benefits are manifold: They not only lead to a significant increase in product quality and cost efficiency but also promote flexibility and adaptability to market changes. In addition, active involvement in continuous improvement fosters employee satisfaction and contributes to sustainability by utilising resources more efficiently and reducing environmental impact. Overall, lean optimisation strengthens competitiveness by leading to an even leaner, more responsive and more customer-oriented organisation.

Logistics centre with automated storage and retrieval system

The logistics centre on the NETZSCH Campus has a modern, automated storage and retrieval system ensuring efficient and fast logistics processing. With 6,937 pallet spaces in the 20-metre-high automated pallet warehouse and 8,480 small parts containers in the 14-metre-high automated small parts warehouse, NETZSCH relies on future-proof storage solutions. The high performance of the systems ensures rapid availability of materials and products. In addition, the material flow has been optimised by integrating of smooth-running cranes and manipulators during order picking and increased precision in warehousing. Furthermore, the material supply through transport train enables a continuous and systematic supply to the production lines, a process that benefits you as a customer.

Cutting-edge and fully automated sawing centre on the campus

By implementing a fully automated sawing centre, NETZSCH has taken a significant step towards increasing efficiency and optimising processes. The sawing centre is equipped with an innovative material flow and storage system controlled by a goods management system. This leads to a reduction in manual labour and, at the same time, improves the precision of material management. The system consists of a bridge storage system with long goods cassettes offering a total capacity of around 1,600 tonnes and enabling an end-to-end automated material flow from storage to sawing. Two high-performance automatic band saws are used for processing the sawing orders, which are characterised by precise saw cuts and reliability in unmanned operations. Through automation and systematic organisation, throughput times have been reduced, storage capacity has been used even more efficiently, and process transparency has been increased.

Precision in production: Round parts and machining processes

Another value chain area is the production of round parts. The processes were also optimised and equipped with state-of-the-art machines and technologies as part of the plant merger. This area is designed to produce the round parts used in NETZSCH pumps. Using the latest CNC technology achieves maximum precision in machining parts, ensuring the high reliability and durability of the end products. In addition, the processes are optimised to enable maximum efficiency and material utilisation, thereby conserving resources and promoting sustainability in the production process.

Innovation meets expertise: Stator production in Waldkraiburg

At the NETZSCH Campus in Waldkraiburg, stator production is central, utilising the latest techniques and processes to produce high-quality stators for NETZSCH pumps. This area combines precision engineering with automation to ensure quality and consistency. Stator production at NETZSCH relies on a careful selection of materials and precise processing to ensure the performance and longevity of the pumps. This enables us to guarantee a particularly long service life and minimal downtime. Continuous research into elastomers and new production techniques is a prime example of how NETZSCH combines innovation and sustainability to fulfil customer requirements best.

Welding shop with the latest technology on the NETZSCH Campus

The NETZSCH Campus welding shop represents a significant advancement in manufacturing technology and the working environment. NETZSCH has created an efficient and integrated production line by bringing all areas together in one central location. Tube rotor production now runs smoothly from pressing to sawing to welding, which has made it possible to reduce throughput times. State-of-the-art welding equipment and modern recirculating air extraction systems at all welding workstations ensure optimum working conditions. A pickling system was also installed, which further increases throughput times. The additional introduction of the transport train in the metal processing department demonstrates the continuous optimisation of logistics and production processes.

New coating centre: Progress for quality and sustainability

The new coating centre at the Waldkraiburg site increases product quality and improves the efficiency and environmental compatibility of the manufacturing processes. By integrating the latest technologies into the coating process, NETZSCH can guarantee a consistently high surface quality of its products, which leads to a longer service life. This is precisely what you benefit from as a customer. Process optimisation in the coating centre reduces processing times, which results in more efficient production planning. In addition, the coating centre's modern equipment helps to minimise the need for chemicals and solvents. This has not only improved working conditions for employees but also sustainably reduced the environmental impact. The technological highlights include the washing and powder coating process, semi-automated powder coating, a manipulator for optimised stator handling, two combinable wet painting booths for large parts up to 13 metres in length, a modern extraction system, a paint preparation system for disposal and the centralisation of all coating activities. An additional paint store with a mixing room complements the coating centre. Thanks to its heat recovery system, the new coating centre is also exceptionally environmentally friendly compared to older models.

Assembly processes: Specialisation and increased efficiency

In the assembly area on the NETZSCH Campus, efficiency and quality are guaranteed at the highest level thanks to sophisticated organisation and technological support. The workstations are subdivided according to pump sizes and types, which enables a specialised and focused way of working. The arrangement of the assembly and test bench workstations in one line promotes a flowing and logical production process. This minimises throughput times and increases productivity. An inventory-controlled delivery strategy using a transport train ensures optimum material availability and reduces storage costs and downtime. The search effort for employees has also been reduced due to the finding of the destination and precise localisation of orders. The separate repair workstation also enables maintenance and repair tasks to be processed quickly and efficiently without disrupting the regular assembly process. In addition, a separate oil storage area and mobile oil stations ensure a safe and clean working environment and minimise the risk of contamination.

Maximum precision and efficiency in pump testing

The test bench is a central component in the quality assurance of pump production. The test areas are organised precisely according to size and offer a smooth transition into the testing process thanks to their close connection to the assembly areas. A highlight is the new, separate hygiene test bench, which has been specially designed to meet the requirements of the hygiene sector. The introduction of automatic data transmission enables seamless documentation. The test benches also have functions for negative pressure tests (NPSH) and temperature control. This enables comprehensive and needs-based testing of the various pump types. High-pressure areas are analysed using impression tests. The comprehensive crane system also improves the handling of large pumps. With the purchase of a new small pump test bench and the expansion of the large pump test bench, NETZSCH ensures that every pump size is optimally tested to guarantee the highest standards of quality and performance at all times.

Advanced shipping solutions on the NETZSCH Campus

Efficient and ergonomic solutions were implemented in the dispatch area of the NETZSCH Campus to optimise the dispatch process and minimise the physical strain on employees. The packaging stations, subdivided according to pump size, enable a systematic and organised way of working and speed up the packaging process. A separate area for packaging spare parts and small parts also ensures a clear separation of the various shipping tasks and increases efficiency. Moreover, the combination of smooth-running cranes and manipulators for handling the finished components and goods reduces the risk of damage during the packaging process and minimises the physical strain on employees. In addition, the new loading concept enables fast and efficient lorry handling, which reduces waiting times and increases customer satisfaction through punctual deliveries.

From goods receipt to dispatch, the NETZSCH Campus in Waldkraiburg stands for the highest quality and efficiency in all work steps combined with optimal working conditions for employees. This is how we guarantee you Proven Excellence in the future – outstanding performance in all areas.