Products/Services

The main characteristic of our production is the vertical range of manufacture. The required plastic components are extruded and injected in our company. Our NC high-performance cold circular saw cuts the bar material for the spindle extensions with millimetre precision. Complex components are turned and milled in the CNC department. Our specialists then assemble the individual parts and pre-assemble the assemblies.

The first milling machine including automation system was purchased to drill holes in square protectors and coupling sleeves according to customer requirements. Today we are much further ahead. From the small department grew a supporting pillar of Schönborner Armaturen GmbH. As a contract manufacturer, we process prototypes and small series for various industries and manufacture injection moulding tools for our plastics production.

Our own requirement for protective tubes is about 800km per year. This is longer than the distance from Hamburg to Munich. For this reason we invested in our first plastics machine, an extruder, in 2008. In the meantime two injection moulding machines have been added. On these we produce the individual parts for our installation fittings. Herewith we are available as a contract manufacturer including toolmaking.

Materials used and manufacturing process

Plastics processing – precision from a single mould

Safe and precise closing connections are required for the supply of water and gas to private households and public institutions and for the discharge of waste water. For many decades, the operation of the valves should be guaranteed without any functional restrictions. In order to meet this functional reliability, we develop and manufacture specially designed protection tube systems. Plastic extrusion for pipe production as well as injection moulding for the production of cover caps, round bells, adapters etc. form the basis for this. Standard plastics, but also specially developed plastics are used to produce precision parts with a high degree of shaping variety and flexibility.

Safe and precise closing connections are required for the supply of water and gas to private households and public institutions and for the discharge of waste water. For many decades, the operation of the valves should be guaranteed without any functional restrictions. In order to meet this functional reliability, we develop and manufacture specially designed protection tube systems. Plastic extrusion for pipe production as well as injection moulding for the production of cover caps, round bells, adapters etc. form the basis for this. Standard plastics, but also specially developed plastics are used to produce precision parts with a high degree of shaping variety and flexibility.

YOUR ADVANTAGES

  • high variety and accuracy of shape
  • short production times
  • low component costs
  • low weight
  • heat and sound absorbing and electrically separating
  • weather and chemical resistant
  • no post-processing
  • good colouring even without painting

The necessary work steps leading to the desired component are carried out quickly. Using an injection moulding tool, the plastic heated to melting temperature is injected under high pressure into the cavity of a mould. In order to permanently maintain the required dimension of the mould, the material is then pressed under low pressure until the plastic is compacted. It then cools down and the workpiece is automatically removed from the tool. Compared to other materials such as glass or metal, the plastic allows mass production of components within an optimised cost framework.

Nevertheless, a high quality and enormous resistance of the product is guaranteed. Detailed components can be produced in high quantities in a short time. Manual finishing is possible, but not absolutely necessary. Due to the numerous advantages of plastic, we also use a wide variety of thermoplastics for our products, as well as talcum or glass or natural fibre reinforced materials. We use processes such as extrusion and injection moulding. For example, with a clamping force range of 500-1,500kN and depending on the workpiece, we realise part weights of 4-200g in injection moulding and extrude pipes in the diameter range up to approx. 70mm.

Stainless steel – Quality by brand

Stainless steel, probably the most commonly used production material today for areas where moisture plays a decisive role. For this reason, the trademark “Edelstahl Rostfrei” (stainless steel) was introduced as early as 1958 to clearly identify products of quality-conscious manufacturers, processors and suppliers. We are also allowed to use this trademark for our products because we offer quality that is recognisable at first glance.
Of the 120 different types of stainless steel known today, the most frequently used stainless steel is material number 1.4301. A high proportion of 17.3-19.3% chromium, which must be dissolved in the austenitic or ferritic mixed crystal, repels any aggressive substances such as moisture, frost or UV rays and even acids.

YOUR ADVANTAGES

  • high corrosion and temperature resistance
  • good thermal conductivity and permanent tightness
  • top quality
  • optimal hygienic conditions
  • high strength and resilience
  • easy processing and high material elasticity
  • long product life and low follow-up costs
  • low maintenance requirements
  • resistant to frost, UV rays, acids and moisture

V2A or V4A stainless steel is used depending on the area of application. The V2A stainless steel is the stainless steel used in everyday life, e.g. for vehicles or fittings, whereas the V4A stainless steel with about 2% more molybdenum is even more resistant to corrosion and is therefore often used in swimming pools, seawater or the chemical industry. In addition, even temperatures of up to 300 degrees Celsius cannot have a negative effect on the quality of the 1.4301 stainless steel.
The saying “as hard as steel” is therefore true to the extent that damage to the stainless steel by external influences is virtually impossible. The increase in corrosion resistance can be achieved not only by adding molybdenum, but also by adding nickel and other alloying agents.

Zinc flake systems – More than just corrosion protection

Zinc flake coatings usually consist of a combination of zinc and aluminium flakes, which are connected by an inorganic matrix. They are often used where corrosion protection is of great importance. For example, the zinc flake is particularly convincing when working with mass-produced small parts such as screws or spring band clamps due to its extremely low layer thickness and yet high load-bearing capacity.

YOUR ADVANTAGES

  • high load-bearing capacity
  • wafer-thin layer thickness
  • high accuracy of fit
  • no hydrogen induced stress corrosion cracking

At just 8-12μm, the zinc flake is significantly thinner than conventional corrosion protection systems such as powder coatings or hot-dip galvanising – even thinner than a human hair. Nevertheless, it guarantees a protective effect of up to 1,000 hours against base metal corrosion in the neutral salt spray test according to DIN EN ISO 9227. Consequently, the zinc flake coating is particularly suitable for products that require high resistance and accuracy of fit.

If you would like to find out more about zinc flake coatings, please visit the Dörken MKS website. There you will find everything you need to know about coating solutions: www.doerken-mks.de