A great leap in manufacturing

Supported by Bihler technology, Freudenberg wins the German Innovation Prize 2011

"Freudenberg, Trumpf and Bihler have always believed in a successful completion of this project", Mathias Bihler, managing director at Bihler, says with pride. During the award ceremony, his enthusiasm was written all over his face. "Only by means of a trusting relationship between three technology leaders was it possible to bring this complex task to a successful conclusion."

Innovative master stroke

The efficiency of resources convinced the jury of this year's German Innovation Prize. Sealing components are now manufactured by means of an entirely new process on two Bihler BIMERIC systems equipped with a Trumpf laser and 76 NC axes. This process offers decisive advantages compared to the traditional deep drawing process: "As waste material is avoided, material usage is reduced by up to 85%. With 1.800 tons per year calculated with the current price of steel, that means an enormous saving", raves Bihler.

Cheaper than producing in China and India

The NC technology allows the Weinheim based company to produce a great variety of types at maximum productivity. Moreover, the company is able to react flexibly to market requirements. "Thus, Freudenberg produces cheaper and better sealing components than any competitor worldwide", continues Bihler. This strengthens the high-wage location Germany and secures jobs. What is more, the prize-winning process is almost free of wear. This is also due to the special coating of the active tool parts. The use of polluting lubricants as during deep drawing processes is no longer necessary. CO2 emissions are cut by 2.700 tons. This makes the process especially environmentally friendly.

A foundation for the future

"Freudenberg will adapt its worldwide production to the new manufacturing process. In order to satisfy the great demand on the world market, the market leader will certainly need further Bihler machines", says a pleased Bihler.

Award ceremony on March 25, 2011 in the hotel "Bayerischer Hof" in Munich (from left to right) - Hermann Stahl (division manager, Freudenberg), Dr. Martin Stark (member of the management, Freudenberg), Klaus Kärcher (project manager, Freudenberg), Dr. Arman Barimani (member of the management, Freudenberg), Peter Kaupp (head of engineering, Trumpf), Mathias Bihler (managing director, Bihler)