Company prospectus - Thöni Industriebetriebe GmbH

Company prospectus - Thöni Industriebetriebe GmbH

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The Thöni family-run business works in the divisions of aluminium, environmental engineering,
plant engineering, hose production and manufacturing.
In all divisions, we fulfil the highest demands of
our customers with regards to quality, ­flexibility
and innovation. Environmental responsibility
and sustainability are our guiding themes.
Our successes to date have given us the opportunity to further expand and invest in the future.
On-going improvements in our machinery, extensive quality management, state-of-the-art infrastructure, our own research and development
department, perfect training of our a­ pprentices
and students together with countless qualification measures for our employees are the guarantee that we will continue to deliver top-class
quality in every way.
Enjoy this exciting overview of our company
and take a tour through the world of Thöni.
December 2011
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Aluminium
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Environmental / Energy Engineering
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Plant engineering
24 2
Corporate philosophy & Sites
Hose Production
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Manufacturing
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Academy / Sky Lounge
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Aluminium World
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Fascination with Aluminium
Aluminium is a multi-functional, long-lasting and recycl­
able material.
n light n energy-saving n long-lasting
n non-corrosive n tasteless
n robust n versatile
Aluminium is the most common metal in the Earth’s
crust and is about three times lighter than steel and
particularly weather-proof and resistant to deformation.
Since the first industrial production process in 1886,
the metal of modernity has experienced an incomparable upsurge. The reason for this unparalleled triumph
are the outstanding properties of this material, which
repeatedly fascinates us at Thöni.
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Through the widest range of workability and the diversity of design options, aluminium has become the
most important material of modern architecture. Today,
aluminium is the most frequently used metal for windows, doors and facades. Effective lightweight design
in automobile engineering is also inextricably connected with aluminium. The proportion of aluminium is
constantly increasing in both the top-of-the-range and
small and mid-range vehicles. Considerably weight
reductions save energy and reduce emissions. Whether in medical engineering or in the field of renewable
energy, aluminium components from Thöni stand for
quality and cost-effectiveness. Through the high level
of automation of the connected production lines and
the extensive production options on-site, the shortest
reaction times can be realised.
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Aluminium Extruded Billets
Approximately 80% of the aluminium produced in the
last 100 years is still in global circulation. By recycling
aluminium scrap, Thöni ensures the closing of this
cycle and contributes to ensuring the European raw
material base, using minimal energy levels.
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Thöni Deutschland GmbH produces 60,000 tonnes of
high-quality extruded billets a year from secondary and
primary aluminium. These are manufactured to meet
the relevant customer specification in diameters between 152 and 254 mm. This applies both for the composition and the homogenisation conditions.
As well as the long-term, reliable and continual delivery
of extruded works, we are also in the position to react
at short notice to customer requirements.
Our key focus is 6000 series alloys.
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Extruded profiles with the highest precision
for demanding profiles
In close cooperation, we produce aluminium profiles
to meet the specifications and requirements of our
customers. As a result shared, progressive complete
solutions are achieved.
Thöni stands for:
n High level of applied knowledge for fulfilling even the
most difficult challenges regarding surfaces, ­density
and forming characteristics.
n 4 extrusion presses with 12.5 MN, 16 MN, 25/27
MN and 32/35 MN press capacity for manufacturing
complex high-precision profiles. With the highest precision and surface quality, we are able to press profiles
with a circumference between 15 mm and 310 mm
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and a weight per meter of 0.15 kg to 15 kg, while complying with the strictest tolerances.
n Processing of alloys: EN AW 6060, 6063, 6005A,
6082. We offer individual solutions for special requirements.
n Technical support of our customers in the development of new profile geometries and components.
n A capacity of 56,000 tonnes of aluminium profiles
per year. The high degree of automation and the high
level of qualification of our employees lead to an optimum degree of productivity and delivery reliability.
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Automotive - Unlimited use of aluminium profiles
Development and production of precision profiles including the mechanical processing and assembly for projects from the automotive and mechanical engineering
divisions.
You’ve come to the right place if you are looking for the
mass production of components made from processed
aluminium profiles.
Thöni Automotive Components primarily produces for
the European automobile industry and is a competent
partner for semi-finished products, processed profiles
and components. The product range mainly comprises
structural parts and engine casing components.
In the field of crash-relevant applications, some projects could be implemented as TIER1 suppliers. In particular, braces and side impact absorbers have been
implemented.
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We can supply any possible mechanical further processing if the quantities and investment costs are in
practical proportion.
Your advantages:
n You have one contact person from primary material
to the finished components.
n We are a one-stop supplier.
n We are able to professionally handle investment projects for customers within a relatively short period
of time.
Certification in accordance with TS 16949 and compliance with strict environmental standards are par for the
course here. A high level of process orientation is the
most fundamental key factor of our success. State-ofthe-art equipment in our test centres guarantees the
best quality for our customers.
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Decoration and protection - more than just refinement
Thöni is also your ideal partner in the field of surface
technology. State-of-the-art production options combined with years of experience allows us to anodize
aluminium profiles up to a length of 8 meters.
The anodic coating (5-25µm) protects the aluminium
from environmental influences, makes it easy to clean
and provides Thöni profiles with a highly decorative appearance.
Addressing environmental concerns, Thöni operates
the anodising plant and wastewater treatment plant in
accordance with the latest technical findings.
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Quality and environmental management
We endeavour to provide the highest possible level of
satisfaction for our customers by focusing our efforts
on them. We consider the implementation of our customers’ requirements, our quality management system and, above all, the spirited debate with quality as
the tenor in all areas of life to be our guarantee for the
future.
Process orientation, concentration on the requirements of the customer and the absolute commitment
to continually improve our services are the prerequisite
for success with regards to the increasing globalisation
of companies and markets.
We rely on precautionary quality planning and consistent quality assurance, whereby we draw on state-ofthe-art test systems.
As well as quality, the environment is also very important. We are conscious of our responsibility to handle
resources carefully and to select technically feasible
but ultra-environmentally friendly methods.
Our certificates:
ISO TS 16949, ISO 9001, CE certificate in accordance
with EN 15088
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Environmental / Energy Engineering
Since the beginning, Thöni Environmental Energy/
Engine­ering has dealt with the development and realisation of innovative plant technology to extract renewable energies from organic waste and renewable raw
materials.
From the planning to construction to commissioning
and the aftersales service, Thöni offers turnkey biogas
plants that are used throughout the world. A highlyqualified team provides advice and support for our customers from the very beginning until successful commissioning of their biogas plant.
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These systems are planned and designed in our own
engineering division.
They are produced in our metalworking plant in
­Landeck. As we are the manufacturer, we are ­intimately
familiar with every detail of our systems and can therefore be flexible in meeting the specific needs of our
customers.
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Fermentation of renewable resources
For the agricultural division, Thöni offers turnkey biogas
plants for the fermentation of agricultural by-products
and renewable resources.
Biogas is produced from the organic resources, which
is then converted into bioenergy, in the form of electricity and heat, in co-generation plants.
The “green electricity” obtained in this way is fed into
the public network, while the “green heat” can be supplied to a district heating network or used to dry feed
and wood.
And in this way, the green cycle is closed: The fermentation residue is used in the fields again as solid and
liquid high-quality fertiliser.
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Fermentation of organic waste
With the energy from one kilogramme of kitchen
­waste, it is possible to drive a car one kilometre.
A fact that Thöni implements with its specially developed procedure to ferment solids with technical knowledge. These systems are used to obtain biogas from
bio waste or organic waste. The biogas is then converted into green electricity and heat in co-generation
plants or prepared to be fed into the natural gas network.
With the energy from 10,000 tonnes of bio waste,
about 500 households can be provided with electricity
and heat for a whole year.
After the fermentation process, the fermentation residue is dewatered in Thöni screw presses. This creates valuable, biological liquid fertiliser and high-quality
compost.
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Photovoltaic Power Station
Since December 2011, our Kempten/Germany site has
been operating a photovoltaic power station, consisting of 4,200 solar modules, which produce 1 megawatt (1,000 kilowatts) of solar energy.
This energy is fed into the European power network.
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Plant engineering
For over 20 years, Thöni’s mechanical and plant engineering sector has had its own production plant in the
Landeck metalwork plant.
All systems and components for the environmental
­engineering, casting equipment and aluminium processing divisions are built at this location.
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In addition to orders from our own business sectors,
we also manufacture products for external customers.
Renowned international companies from the lift and
cable car sector, mechanical and plant engineering industries and power plant and turbine manufacturing
sectors have been some of our satisfied customers for
many years.
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A team of highly-qualified specialists
A high degree of technical competence and creativity
in our employees ensure the best quality for our customers. In cooperation with universities, our customers
and partners, our highly-qualified engineers develop
state-of-the-art process technology and plant concepts
through to start of production.
Our innovations are continually checked for their
cost-effectiveness and are protected by a number of
­patents.
All the systems we produce are constructed in our factory prior to delivery, tested for their functionality and
undergo a quality inspection. This optimises on-site assembly and commissioning.
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State-of-the-art technology for plant engineering
The Thöni Casting Equipment division has planned,
produced and delivered horizontal continuous casting
plants for the production of sheets, profiles and round
formats from copper and copper alloys, aluminium tin
and precious metals for decades.
Consistent further development of our systems and
technology guarantee the best casting results and
make it possible for us to fulfil specific customer requirements as well.
Satisfied customers are our best references. The
world‘s largest strip casting plant for non-ferrous
alloys in Germany operates exclusively using horizontal continuous casting plants manufactured by Thöni.
Even the production lines to produce Euro coins are
manufactured with our systems.
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Corporate philosophy
The corporate philosophy shows what we stand for.
It forms the framework, in which our vision, strategy, values and principles are anchored. The corporate
philosophy shows us the way, builds the foundation
and stipulates the rules of our action.
What values are we committed to?
Family-run company
We are a medium-sized family-run company with a
strong connection to our roots and a growth-oriented focus. We place major significance on corporate
­autonomy.
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Customer focus
Our utmost objective is the satisfaction of our customers. For this reason, it is our duty to recognise the
needs and expectations of our customers in order
to be able to fulfil these rapidly and effectively. Our
ambition is to make things better than our competitors can.
Our employees
We rely on our employees and their further development because the quality of our services depends
definitively on them. The Thöni Academy is our p
­ ower
house for the mental and physical vitality of our
­employees.
Quality and continual improvement
The objective is the development, construction and
manufacture of products and services with top international quality at competitive prices. Our demand
of ourselves is to continually improve our services
and to scrutinise existing procedures and behaviour,
making changes where necessary. We operate an efficient quality management system.
Innovation
We develop pioneering procedures and products and
are pioneers in the technical implementation of our
production processes.
Environmental protection
We take care to use products and resources with a
high level of recycling, to produce in an eco-friendly
manner, to avoid unnecessary waste streams and to
prefer new, environmentally friendly procedures and
technology.
Responsibility and sustainability
Social, ecological and economic responsibility defines our corporate action. Sustainability has the top
priority in our strategic and daily decisions.
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Sites
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Aluminium Worlds Telfs
Telfs Factory I
Thöni Academy and Factory II
German Site: Kempten
Vehicle Fleet
Landeck Factory
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Hose
On our modern circular looms, we use high tenacity
polyester yarns to produce the weavings for our huge
range of hose types in diameters between 3/4“ and
6“. Interior liners, for the most part EPDM-Manchon or
other high-grade liner types, are subsequently inserted
into these weavings, which are then rubberized in a
computer-controlled vulcanizing plant.
Our hoses can also be outer-coated upon special request by the customer.
During the production process and after completion, all
hoses are subject to an interim and / or final inspection
according to EN ISO 9001:2008.
Due to our efficient and prompt processing of orders /
production planning, we guarantee our partners short
and reliable delivery times.
Our product range is internationally respected and has
an excellent reputation worldwide.
Outstanding quality at competitive prices, flexibility
and speed - in short: the hose you can rely on.
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The hose you can rely on.
Since 1970, the hose division has produced more than
70,000 km of hoses - that is equal to a distance of
more than 1.5 times around the entire globe.
Thöni hoses are distributed throughout the world and
are mainly used for fire fighting, in industry, mining and
agriculture, for snow-making equipment and various
other special applications.
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Manufacturing
With Thöni Manufacturing GmbH in Kempten, the
­Thöni group has a production site for the metal-cutting
processing of high-precision, medium-sized, cubical
work pieces.
At this site, the most demanding requirements of our
customers are fulfilled with the use of world-famous,
high-precision and fully automated machinery.
With the fully automated production systems, highprecision parts from the mechanical engineering, plant
engineering, gear manufacturing and compressor construction sectors can be processed up to a maximum
of 5,000kg.
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The milling machines, drills and jig boring machines
which are connected by an automatic pallet transport
system, together with grinding centres and measuring
machines are installed on a fully air-conditioned production area of approx. 8,000m² and an additional storage
area of approx. 3,000m². Blanks and finished components are transported from the goods-in department
to the goods-out department using an automatic transportation system controlled by the central computer.
Thanks to our own construction and programming department, we can contribute helpful and cost-reducing
ideas and concepts for our customers, on request,
from as early as the construction phase. But it is not
just in the construction phase that we can help to save
costs. We can also reduce expenditure in the final assembly phase using coordinated components by providing important functional measurements.
In the fully air-conditioned production hall, there are also
areas for the assembly of components and m
­ odules. A
continuous process chain allows us to offer such highquality system solutions.
Quality standard:
Continuous process chain from tender to the delivered
components.
Master production computers make it possible to
design the production procedure transparently and
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­reproducibly.
All parts produced by us are subjected to a quality
­inspection in our factory before delivery.
Thöni Manufacturing GmbH – your competent partner
for demanding, innovative and successful collaboration.
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MCM Action 2600 flexible
production system
With our new, flexible and ultra-modern system, we
can economically produce small and medium series.
With the two Action 2600 processing centres, which
are connected to one another through the twentyfold pallet system, we are able to produce the highest
­quality work pieces.
The entire tool magazine with almost one thousand
­positions guarantees us the ultimate flexibility.
Data transmission by data chip and tool breakage
checks ensure our high quality requirement.
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Processing centres
Structured, ordered machinery and highly-qualified
employees are the guarantee for outstanding and
consistent precision and a high level of productivity.
We ensure the highest level of flexibility through our
­redundant production machinery.
Pallet transportation system
Our pallet transportation system connects all production machinery and enables fully automated operation
in connection with the master production computers.
Storage rack system
Set-up/loading points
Starting in the goods-in department, the parts are directly passed through the automatic system into the
production department. Storage areas in the goods-in
department for blanks and storage areas in the air-conditioned hall guarantee a constant temperature of the
work pieces, even between working steps.
Detailed set-up and clamping plans ensure that
­employees always clamp the work pieces in a capable
way.
Then the pallets are placed into the buffer zone between the two transport lines before they are automatically fed into the machinery as per the production plan.
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Grinding centres
We achieve the finest and ultra-precision surfaces
with the CNC flat grinding machines. Thanks to the
­integrated hollow/spherical grinding equipment, we are
also able to react to changed accuracy requirements,
such as convex or concave contours.
Central cooling
lubricant systems
In two central systems, the cooling lubricant used is
cleaned in a fully automated manner and re-fed into
the machines. Due to continuous monitoring and regular laboratory checks, we also guarantee our quality
requirement here. The chips are directly disposed of by
a central chip conveyor.
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Quality assurance
Work scheduling
Using our high-precision PMM 402016 bridge-type
measuring machine, we carry out process analyses
according to the relevant methods and produce test
documentation according to requirements.
3D solids are the basis of the CAD/CAM systems we
use. From the equipment construction through the NC
programming, to 3D collision inspection, all systems
are comprehensive meaning all the information
checked is available for the production department at
the end.
For continuous process checks, we use our MORA layout measuring machine. The testing accuracy is stored
in the master production computer processes so that
the work pieces are automatically transported to the
measuring stations.
Manual measuring stations with 3000mm x 1600mm
granite measurement plates, a Mikro-Hite 800 height
gauge and Whyler flatness measuring devices
complete our measuring options.
Tool management
The central focus of the tools used is the tool
management system. All tools are recorded here with
an image and the stock list. The cutting data is also
managed centrally, which always achieves the best
results.
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Dynamics and creativity
Study tank:
Technical grammar school
The Thöni Academy is our “power house”, consisting of
four pillars, for the mental and physical vitality of our
employees, customers and partners.
The five-year upper stage of our school offers vocatio­
nal training with apprenticeship graduation, which can
be carried out in either mechatronics or automation
technology, together with a substantiated general
­education (AHS Matura).
An overview of the four pillars:
n Study tank
n Think tank
n Information tank
n Body tank
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®
akademie
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Study tank: Apprenticeship workshops
In our apprenticeship workshops, we are currently providing training for the skilled trades of machinery repair
technician and machine tool technician. Since autumn
2011, legislation has defined that the new modular professionals for metal technology must be taught.
The following 1.5 years of the apprenticeship ­comprise
the main module of machine tool technician. Indepen­
dent processing of work pieces with computercontrolled CNC machinery. Basic knowledge about
pneumatics, hydraulics and control engineering.
The following tasks, in particular, are connected with
the individual modules:
After these 3.5 years of the apprenticeship, the final
apprenticeship examination can be taken. With an outstanding result, there is the option of taking a special
module which consists of 0.5 years of the apprenticeship.
The first 2 years of the apprenticeship comprise the
basic module of metal technology.
Basic knowledge of the materials being processed and
the machine tools, measuring aids and resources connected with this.
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1st special module - Automation technology:
Modules of control and regulation technology and modules of pneumatics and hydraulics. Parameterising of
PLC controllers.
2nd special module - Construction technology:
Computer-supported drawing and construction of complex work pieces (CAD, CAM) and planning of ­machinery
and system components.
3rd special module - Process and production technology:
Basic knowledge in the field of project management and
project handling. Goods procurement and flow of goods.
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Information tank: Research and development
Innovations determine success and advancement. The
Thöni Academy develops the products of tomorrow:
n Innovation, technology and engineering
suppliers within the Thöni group
n K
nowledge transfer from science and
applied research
n Innovation and knowledge management
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Body tank: Healthy body - healthy mind
The versatile range of services promotes vitality,
life quality, motivation and the physical and mental
well-being of each individual. Physical problems are
­improved, while reinforcing health.
The Body Tank is an important step in terms of innova­
tive operational health management in our company
and a sign of our appreciation of our employees.
n Personal consultation and support
n An on-going range of special courses
n Lectures on health-related topics
n Partner day for joint training
n Apple, water and other special projects
n Annual health day with “diagnosis route”
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Think tank: Meeting at the highest level
In the unique Thöni sky lounge, employees, business
partners and friends of our company meet to ­discuss,
learn or simply make cosy small talk in a unique
­atmosphere.
With an imposing view over the Tyrol uplands and the
impressive mountains around Telfs, events from the
fields of economics, politics and art and culture take
place here together with company celebrations and
meetings.
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skylounge
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Aluminium World Experience
The Aluminium World offers an overview of the discovery and manufacture of aluminium, through to its
processing and a huge range of different applications.
History
A foray through the history tells the tale of the first
trials with aluminium through to the outstanding successes in technology and science. The versatility of
today’s usage, the economic significance, through to
the future visions with the resource of aluminium are
presented in 3D using the “Aluversum”.
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Company divisions
Visitors can experience aluminium in all its guises
and gain an overview of the company group and its
­services. Exciting attractions with all the senses ­ensure
an unforgettable experience.
Tour
The visitor then has the opportunity to witness one
of the many processing forms of aluminium up close,
­directly on site. You will experience “live” the manufacture of our customer profiles as part of a tour.
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Immerse yourself in the fascinating world of aluminium
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Thöni Holding GmbH
Obermarktstraße 48
A-6410 Telfs
Tel. 05262/6903-0
Fax 05262/6903-210
thoeni@thoeni.com
www.thoeni.com
Thöni Industriebetriebe GmbH
Aluminium, Schlauchproduktion,
Umwelt- und Energietechnik
Obermarktstraße 48
A-6410 Telfs
Tel. 05262/6903-0
Fax 05262/6903-210
thoeni@thoeni.com
www.thoeni.com
Thöni Industriebetriebe GmbH
Metallwerk Landeck
Uferstraße 6
A-6500 Landeck
Tel. 05262/6903-0 und
Tel. 05442/628 11
Fax 05262/6903-650 und
Fax 05442/628 11-650
thoeni@thoeni.com
www.thoeni.com
Thöni Deutschland GmbH
Dailmerstraße 21
D-87437 Kempten/Allgäu
Tel. 0049-(0)831-5-74 20 00
Fax 0049-(0)831-5-74 20 40
thoenideutschland@thoeni.com
www.thoeni.com
Thöni Manufacturing GmbH
Dailmerstraße 21b
D-87437 Kempten/Allgäu
Tel. 0049-(0)831-5-74 37 0
Fax 0049-(0)831-5-74 37 64
manufacturing@thoeni.com
www.thoeni.com
Thöni Automotive
Components GmbH
Obermarktstraße 48
A-6410 Telfs
Tel. 05262/6903-0
Fax 05262/6903-210
thoeni@thoeni.com
www.thoeni.com
Abfallverwertung
Unterland GmbH
Obermarktstraße 48
A-6410 Telfs
Tel. 05262/6903-0
Fax 05262/6903-210
avu@thoeni.com
www.thoeni.com
Biogas Zeltweg GmbH
Obermarktstraße 48
A-6410 Telfs
Tel. 05262/6903-0
Fax 05262/6903-210
bga-zeltweg@thoeni.com
www.thoeni.com
Thöni Italia Srl
Waltherplatz 22
I-39100 Bozen
thoeni@thoeni.com
www.thoeni.com
Thöni Italia Srl
Centro Area 22
Via per Marco Nr. 12/B
I-38068 Rovereto (TN)
thoeni@thoeni.com
www.thoeni.com