issue 1 / 2009 / inside …donar.messe.de/exhibitor/hannovermesse/2017/g96094/...inside hydraulik...

Inside HydraulikThe Official WATZ Hydraulik Newsletter

Issue 1 / 2009 / www.watzhydraulik.de

When it comes to efficientpower transmission, you can relyon WATZ Hydraulik

Always on the move

Over the past few years, hydraulics

engineering has been increasing in

significance in all areas of drive and

control technology, in particular, the

fields of machine, plant and vehicle

construction. At the same time, client

demands on quality and efficiency of

the systems in use have also increased

greatly. WATZ Hydraulik has been

meeting the challenges of these markets for over 35 years.

Moving in sync with the market and the constantly chang-

ing technical demands, WATZ Hydraulik has never slowed in

offering its clients innovate and industry-spanning hydraulics

products. With hydraulics engineering being, as a rule, an in-

tegral component of an overall system, WATZ constructors

and technicians have been trained to collaborate with mech-

anical engineers and plant constructors in elaborating plans,

schedules and everything else needed to carry out a project

successfully. This is the only way to develop optimum sol-

utions while avoiding later alterations and modifications,

which are always costly and often unnecessary. WATZ Hy-

draulik produces made-to-order constructions and refines

these as specific large-batch or small-batch production

models according to customer requirements. The follow-

ing pages will offer you some insight into the diversity of

WATZ Hydraulik’s range and service spectrum. Countless

industries around the world stay on the move thanks to

hydraulics products produced in Central Hesse – from

materials handling technology and foodstuffs preparation all

the way to the demolition of chemical weapons. Wherever

one requires the efficient transmission of power, you’ll find

WATZ products doing the job.

And if you turn over this newsletter, you’ll be able to

become better acquainted with FAUDI GmbH. At home in

the filtration industry, this long-standing firm entered a busi-

ness partnership with WATZ Hydraulik GmbH in 2006. Both

companies are experts in the field of special purpose machin-

ery manufacture. Using this and many other synergies is the

secret behind the success of our business collaboration. We

hope you’ll find this newsletter informative and inspiring.

Best regards, WATZ Hydraulik GmbH

Horst Watz

2 | 3

Contents

3 Pressure: The most natural thing in the world – for WATZ

4 Where quality saves lives

5 Successful plant engineers rely on WATZ hydraulics technology

6 Perfect porcelain requires perfect technology

7 Precision meets performance

8 Finding solutions where no solutions can be found

9 Why look far ...

Big performance, small space!

10 Moving water in massive amounts

11 Digging for black gold

12 Rings and wheels for the automotive industry

Imprint

WATZ Hydraulik GmbH

Auweg 8 · 35457 Lollar · Germany

Phone +49 (0)64 06 91 02-0 · www.watzhydraulik.de

Inside Hydraulik – The Official WATZ Hydraulik Newsletter

Learning from Mother Nature? That’s nothing new. The

lessons of nature have, after all, been behind countless life-

changing inventions. Today, nature continues to serve as

a shining example for process efficiency and state-of-the-

art technology. At WATZ Hydraulik, we too are inspired by

nature when it comes to developing new hydraulics tech-

nology. And it’s no surprise, really, with nature performing

massive force transmission, often on the smallest scale, or

changing momentum at will. Care for an example? Let’s take

the sperm whale, which uses an ingenious system to reach

the oceans’ deepest depths.

A sperm whale’s brain is known to hold some 2,000 kg

of “spermaceti”. This wax-like substance enables the sperm

whale to dive to great depths while also helping to control its

buoyancy. The density of spermaceti changes with the influx

and efflux of water. It makes it possible for the whale to dive

with a minimum exertion of energy. With a decrease in tem-

perature, spermaceti forms brilliant white crystals. This den-

sification leads to an increase in weight, thereby enabling

the sperm whale to sink more easily. When hunting at great

depths, sperm whales use up their oxygen, thus generating

heat and melting the spermaceti. Despite utilising hydrody-

namic force, i.e., by swimming, the sperm whale is never-

theless able to continue its dive. Once it is ready to resurface,

the sperm whale simply expels the sea water from its body

and begins to ascend.

Nature gifted the sperm whale with this natural technol-

ogy. If it hadn’t, WATZ would surely have helped the sperm

whale on its way. Aside from the development and production

of customised hydraulic systems, WATZ also sets itself apart

from its competitors by offering comprehensive customer

service. At WATZ, we support our customers as early as the

planning stage, ensuring that clients receive individual care

and attention, customised to suit their individual demands.

Work processes are coordinated automatically, thereby guar-

anteeing absolute precision in handling and application. And

that saves both time and money!

Pressure: The most natural thingin the world – for WATZ

Examples of Nature


Chemical warfare ranks as the most dangerous, the most

deadly and the most feared method of waging war. At the end

of World War II, the use of chemical and biological weapons

was prohibited by the international community. Since then,

aside from the numerous violations that have occurred

despite this decree, mankind has also had to deal with another,

similarly important issue: What to do with the chemical

weapons that already exist? These arsenals of doom harbour a

great potential of danger in more ways than one. Their use on

humanity is of course the primary risk. However, the improper

storage of such weapons is no less dangerous. Environmental

catastrophes of unimaginable scale loom on the horizon.

Large caches of chemical weapons are still in storage across

Eastern Europe and the former Soviet Union. In 2006, several

German companies helped to establish special facilities for

the demolition of chemical weaponry in the Russian cities of

Kambarka and Potchep. Each of these plants prepares up to

1.000 kg/h of reactive matter for incineration. Special technology

provided by WATZ Hydraulik is in operation at both plants. The

Stuttgart-based company Eisenmann AG is known to be the

world’s leading system supplier of surface, environment and

process technology. Their expertise in constructing facilities

for exhaust air and waste water treatment and, in particular,

thermal recycling and disposal of waste materials, is of primary

importance in the disposal of chemical weapons. For these

aforementioned applications, Eisenmann supplies a variety

of technically sophisticated components, including explosion

chambers, state-of-the-art robotics for transporting chemical

warfare agents and special ovens in which nerve gas is safely

incinerated. Many of these plants also feature components

supplied by WATZ Hydraulik. In this field, the smallest error

can lead to great catastrophe. The companies charged with the

demolition of these weapons and the manufacturers of the

machinery in use therefore rely only on those components

suppliers able to guarantee the highest-possible product quality.

That is why Eisenmann relies on hydraulics products made by

Where quality saves livesTechnology developed by WATZ Hydraulik in action against chemical weapons

4 | 5


Technology developed by WATZ Hydraulik in action against chemical weapons

WATZ Hydraulik. Due to the very special circumstances of the

project, WATZ was integrated in the planning and construction

phases from the very start. Working closely with Eisenmann’s

development department, WATZ was able to develop optimum

solutions for this highly sensitive area of application. WATZ

provided the entire hydraulics station for the shuttle kiln. The

power unit, installed on a special platform, was charged with

opening and closing the shuttle kiln’s lift gates, which weigh

some 18,000 kilograms. Each lift gate is operated by a separate

power unit. To ensure operating safety, the power units are

switched to the alternate lift gate.

The lift gates themselves are raised and lowered by a

special chain hoist. When lowered, the lift gate touches down

on special rollers and is then pulled up to the furnace chamber

by way of additional horizontally installed, unidirectional

cylinders. This towing action must occur under a specifically

predetermined amount of pressure, as the incineration

process can potentially cause an increase in pressure of up

to +300 mbar. Special safety valves prevent excess pressure

inside the chamber. Furthermore, pressure reservoirs have

been integrated to prevent pressure peaks. In the very unlikely

event of hydraulic system failure, full closure of the lift gates

is nevertheless guaranteed. Moreover, the gates are also

protected against sudden collapse caused by an unforeseen

loss of pressure, as it is possible to open only one gate while

the system is in operation.

With all of these measures in place, this WATZ system is

able to guarantee maximum operational safety. Not bad for an

application that is in use on 350 days a year, with three shifts per

day! WATZ technicians were naturally on hand during system

start-up and visit the site regularly for service and maintenance

calls. System documentation was made available to the client

in Russian, English and German language.

Pictures: Eisenmann AG

More than 100 core sand treatment plants is a fact that

speaks for itself: K & W is one of the most successful plant

engineering companies in this field and its reputation has been

built on quality and constant innovation since its beginnings

in 1907. Its product offering ranges from individual casting

machines to complete – fully or semi-automated – casting

plant, including core sand treatment and regeneration.

Casting machine performance ranges from 10 to 330 casts/

hour. In exactly the same way as Watz, K & W always focuses

on meeting its customers‘ requirements. For this reason,

the casting plant is always tailored to the customer‘s special

needs. The average technical availability of K & W is over

98%. High-precision humidity control and weighing equip-

ment together with robust cooling and mixing design

ensures a consistently high level of sand quality. All K & W

products are characterised by innovation, expertise and

experience combined with sound, high-quality design. And

in order to provide its customers with the trusted high quality

in all areas of plant engineering, K & W also relies on hydraulic

systems from WATZ.

This is true for its projects all over the world. In Brazil, for

example, it built a modern casting facility for an automotive

components supplier which has been manufacturing motors

and clutch systems for many well-known car makers in

Curitiba/Paraná Brazil ever since. WATZ supplied the hydraulic

power systems for this project. The equipment supplied

includes hydraulic power units with a tank volume of up to

32,000 litres.

Successful plant engineering com-panies rely on hydraulics from WATZ

Innovative core sand treatment for foundries


Ceramic production is one of humankind‘s oldest cultural skills.

The combination of time-proven knowledge and the use of

state-of-the-art technologies make it possible to produce the

highest quality ceramics. This is what Eisenmann AG, based

in Böblingen, stands for. Eisenmann is a leading international

system provider in the areas of surface finishing, material

flow automation, ceramics, thermal process engineering and

environmental technology and employs some 2,600 people

in its many locations in USA, Mexico, Brazil, United Kingdom,

France, Spain, Italy, China and Thailand. Eisenmann supplies

complete firing lines for chinaware and sanitary ceramics

Perfect china demands perfect engineering

WATZ hydraulic systems meet royal requirements

6 | 7

with fully automated material flows from the moulding

operation right through to sorting and packing. Well-known

customers such as the Königliche Porzellan-Manufaktur

depend on quality made by Eisenmann. In order to meet the

high demands of its end customers, Eisenmann relies on

components from Watz Hydraulik in its kilns and machinery

such as spray-glazing facilities and driers. For Eisenmann AG,

the name Watz Hydraulik stands for professional know-how,

leading-edge technology and customer-focused service and

guarantees the optimum result for every end customer.

Pictures: Eisenmann AG


The highest possible precision is the essential prerequisite

for achieving lasting success in the components supply

industry. Schuler AG, with its headquarters in Göppingen and

18 further locations on three continents, is a technology and

global market leader in forming technology and puts its full

trust in the quality of the products supplied by Watz Hydraulik.

Watz Hydraulik supplies Schuler, for example, with standard

cylinders in all sizes together with the corresponding special

equipment. Special cylinders in Schuler machinery, for example

built in the form of telescopic cylinders, also come from Watz

Hydraulik. A hydraulic drive unit designed to provide power

to a forming machine using cold forming technology was

supplied to the end user AUDI AG. The hydraulic power unit

is built on a walk-on platform (in accordance with accident

prevention safety regulations). The mechanical cutting

and forming machines from Schuler, equipped with parts

supplied by Watz Hydraulik, meet any challenges made on

them such as increasing quantities, complex part geometry

and processing high-strength materials. The pressing forces

exerted by the machines range from 2,000 to 30,000 kN.

Watz Hydraulik and Schuler – a strong partnership for

innovation and the highest quality.

Pictures: Schuler AG

Precisionteams up withperformance

Hydraulics for forming technology


Providing seemingly impossible solutions

Bending and forming technology

8 | 9

This is the brand

promise of transfluid®

Maschinenbau GmbH.

A promise that the tube

processing specialists from

Schmallenberg have to honour

every single day. Over the last 20 years,

transfluid® has established itself as the

leading manufacturer of pipe bending and end

forming machines in the market. Once a medium-

sized company, the transfluid® brand of today has become

a future-oriented global player. Wherever tubes are bent, cut

formed or cleaned in the world – transfluid® is never far away.

„We are proud to have supported transfluid® in this success

story for more than 20 years“, says Horst Watz, Managing

Director of WATZ Hydraulik GmbH, based in Lollar near

Giessen. The two companies have enjoyed close cooperation

for all of these 20 years. WATZ mainly supplies hydraulic

power units and differential cylinders (in special sizes). The

products have been developed and improved on the basis

of many years of experience. What is special in this is that

WATZ manufactures many of these products especially for

transfluid® in series and thus supplies customised equipment

from series production. Nevertheless, some special power

units and cylinders for tube bending pilot projects are supplied

custom-made. One example is the end customer Deutz. The

specially designed and produced tube bending plant was

assembled directly in the factory.

The power units required were

produced by WATZ in

close cooperation with

transfluid® and in accord-

ance with the end customer‘s

individual specifications. A

further example is MJ Gerüst

GmbH, a well-known German

producer of scaffolding systems. The

plant from transfluid® is installed as stationary

equipment in the factory and performs work in the areas of

clamping, bending and stamping. An appropriate hydraulic

system was designed and supplied by Watz for this. 14

devices (clamping and forming cylinders) are controlled and

supplied with power via a system connection from a central

power unit. The hydraulic power unit is equipped with all the

extras required: reservoirs to reduce pressure peaks and

absorption of fluctuations in pressure and volume flows.

Daisy-chained mounting subplates favoured by Watz ensure

that valves can be replaced quickly and easily. transfluid® has

good reason to rely on the quality supplied by Watz Hydraulik.

Once more, long-standing and above all trusting customer

relationships always pay dividends. transfluid® and WATZ

Hydraulik have proven this in many projects – both nationally

and internationally.

Picture: transfluid® Maschinenbau GmbH


Good partnerships can also often be found on one‘s very

own doorstep. A good example is the firm Howial in

Reiskirchen. The company, a manufacturer of special

machinery for wood processing, is located in the immediate

neighbourhood of WATZ Hydraulik‘s headquarters. It has

been manufacturing finger-jointing machines near the

university town of Giessen for over 30 years. The family-run

company, now in the third generation, plans and develops

a full range of finger-jointing machinery. The Howial name

stands for reliability, high performance, intuitive operation

and robust design. This accords with the demands for

quality that WATZ Hydraulik also places on its product range

Both companies are also owner-managed and have an

Why seekfar afield ...

On the doorstep

Hürner Schweißtechnik – stands for innovation,

performance, customer focus and operational safety with

a widespread network of competent partners around the

world. The company has been in the business of developing,

producing and marketing products for plastic pipe joining

for more than 25 years. The demands for premium quality

that Hürner Schweißtechnik places on itself and on its

services can only be met by incorporating first-class

products in all its equipment and machinery. This is the only

way to ensure the end customer‘s long-term satisfaction.

Hürner Schweißtechnik GmbH is well aware of this and

therefore depends on products from Watz Hydraulik in its

equipment. Special miniature power units from Watz have

High performance in the smallest spaceCustomised lightweights

been incorporated into the portable welding units that are

used by Hürner GmbH. What is important in this is that

all important valve functionality of the pressing and drive

unit is implemented compactly and with no loss of quality

in the control or valve block. And of course, the design

of the units may not exceed a certain format and weight

in order to ensure that the equipment in which they are

used remains mobile and portable. Watz Hydraulik took

up this challenge and has developed a series product

that exactly matches the wishes and requirements of the

customer, Hürner Schweißtechnik. Flexible solutions for

any requirements without compromising reliability and

quality – Watz Hydraulik makes it possible.

international focus. It is therefore not surprising that these

two neighbours have sought out and found each other.

Picture: Howial


VAG GmbH moves water – on any scale. The Mannheim

company is a manufacturer of innovative and reliable valves.

Its product range includes state-of-the-art technology in the

treatment of water and waste water together with many

customer-specific solutions. Wherever water is treated,

moved, stored and distributed, VAG gate valves and butterfly

valves, plunger valves and hollow-jet discharge valves, air

release valves, control valves and hydrants play an important

role. Durability and decades of operational reliability matter.

Repairing or replacing valves that often weigh several tonnes,

such as those used in dams, is very costly. The supply and

distribution of water and the treatment of waste water are

very demanding operations. Valves must be able to withstand

high water pressures and extreme temperature and weather

conditions, irrespective of whether they are used in a desert

or tropical climate. WATZ Hydraulik supplies the right solutions

for even these most demanding scenarios. As VAG GmbH‘s

When large quan-tities of waterneed to be moved

Hydroelectric power plants in Asia

10 | 11

partner, the Central Hessian company is supplying hydraulic

units for two projects currently under way in Indonesia and

China. WATZ is supplying a complete hydraulic unit for the

construction of a hydroelectric plant in Indonesia. The hydraulic

power systems are primarily intended to drive and control the

hollow-jet discharge valves installed. The discharge valves are

controlled via the turbine‘s oil hydraulic system. Should the

turbines fail, the valves will open by themselves within four

seconds at the most. This prevents pressure peaks in the

system. The type ZM differential cylinders supplied are capable

of pressures of up to 250 bar and operate synchronously. The

cylinders of course have the necessary corrosion protection.

Reliability and safety are the key requirements in this project

relating to sluice-gate operations for the 150 km Asahan river

in Indonesia.

Pictures: VAG Armaturen GmbH


The company ITAG was founded back in 1908 and today

employs some 550 people. The ITAG engineering works are

primarily engaged in the manufacture of equipment for the

for the oil and gas industry such as ball valves, drill string

components and wellhead systems. ITAG products are used

all over the world in the production of oil, gas and geothermal

energy. ITAG also performs drilling and workover services for

its customers. It is in this area in particular that hydraulic

technology made by WATZ Hydraulik is used.

The Central Hessian hydraulics specialist supplies, for

example, complete hydraulic power units for ITAG‘s drilling

rigs. What is special about the equipment is the way in which

the technology is powered. The power units are installed

in easily transportable sound-insulated containers and

comply with the strict ATEX directives governing electrical

and mechanical equipment used in potentially explosive

atmospheres. This is particularly important with regard to the

equipment‘s specific use. When drilling down into the earth,

underground gas-bearing formations may be encountered.

Depending on the installation site, escaping gas could

enter the container. Moreover, performance loss due to the

distance to the hydraulically-driven devices must be avoided.

The container is equipped with two power units, with one

of the two 210 l/min units in constant operation while the

second is ready to run in standby, this covering any outages.

The complete motor-pump unit is mounted on a carrier plate,

and the unit can be raised with the help of a double-action

cylinder using a manual pump. This makes any future repair

or maintenance work in the container much easier.

ITAG attaches great importance to innovative solutions for

its components, flexible management, highly qualified staff

and of course reliable components suppliers. For this reason

WATZ Hydraulik is justifiably proud of having ITAG among its

customers.

Picture: ITAG GmbH

Where blackgold gushes

Hydraulics for drilling specialists


Rolling rings and wheels requires special technical and

technological competence. The roots of the SMS Meer

Group stretch back to the year 1872. Sufficient time in which

to develop above-average competence and appropriate

expertise. The Group is nowadays one of the world‘s

leading plant manufacturers, and the SMS Meer name is

well known in the steel, copper and aluminium industries.

SMS provides a complete range of products and services:

comprehensive expertise is provided from the initial layout

to the completed ring and wheel rolling mills. Hydraulic

engineering from Central Hesse is very much in demand for


12

Rings and wheels for the automotive industry

Tradition since 1872

the implementation of individual projects. WATZ Hydraulik

designs and manufactures complete hydraulic power units

with large tank capacities for SMS. The most recent delivery

consisted of a WATZ power packet – a hydraulic power station

comprising power units with 400, 800, 160 and 630 litres

capacity respectively. SMS installed the power station for

one of the world‘s largest automotive components suppliers.

These power units provide the customer, a manufacturer of

components for diesel and petrol injection pumps as well

as gearboxes and engines, with the power to drive pressing

equipment and ejectors reliably. Picture: SMS Meer GmbH

Sollte hier auch was stehen? Sollte hier auch was stehen?

The China National Offshore Oil Corporation (CNOOC) is

China‘s third largest petroleum company. It runs large

cooling systems with sea water in its plant and machinery.

Depending on where the plant is located, this process water

can be contaminated in all sorts of ways, e.g. by algae,

shells or gravel and stones, resulting in unwanted deposits

and blockages in the downstream plant sections, heat

exchangers and pipes. In order to avoid this, CNOOC relies

on continuous-operation filtration systems from FAUDI such

as the fully automated Type 30 backflush filter. The backflush

filter is cleaned without interrupting operations by using part

Clean sea water thanks to automatic backflush filters

FAUDI for CNOOC

Technical Data

Medium: sea water

Flow volume: 760 m3/h

Filtration grade: 100 μm

Design pressure: 13.8 bar

Design temperature: 60 °C

of the flow of the clean flow medium. Each of the installed

filtration elements is flooded one after another in the reverse

flow direction, and the dirt that has been deposited on the

filter surface is removed and rinsed away. The optimum

product characteristics of the Type 30 automatic backflush

filter from FAUDI were the arguments that convinced the

CNOOC to cooperate with FAUDI. This filtration system

represents qualities such as reliability and robust design with

low running costs and no maintenance.

12

Sollte hier auch was stehen?

Andasol 1 to 3 are located in the Spanish province

of Granada, with Andasol 3 still under construction.

They are state-of-the-art solar-thermal power stations that,

following completion, will consist of 510,000 square meters

of collector surface - Europe‘s largest solar power station.

The technically usable potential of solar-thermal electricity

generation exceeds the worldwide demand for electricity

many times over. Solar radiation heats up oil as a heat

carrier to approximately 300 °C, which is then pumped to

circulate through the system and transfer the energy. In this

process, very fine particles develop, which are deposited

on the insides of the piping and which can cause damage.

To prevent this, candle filters with special stainless-steel

backflush filter elements from FAUDI are used in Andasol 1

and 2. The special design of these HTF filter elements means

that, when the backflush valve in the lowest part of the filter

is briefly opened, dirt is washed out of the filter elements

and discharged from the system. This serves to protect the

sensitive machinery from dirt and suspended particles in the

Protected solar powerin Spain

FAUDI for Andasol

Technical Data

Medium: heat carrier oil

Design pressure: 18.5 bar




optimum way. The filters achieve a filtration grade of up to 3

μm. The newly developed gas-assisted backflushing process

and the newly developed filter elements in the FAUDI candle

filters also reduce flushing loss considerably. This protects

the environment through less waste and also allows financial

savings to be made due to lower amounts of expensive oils

being lost. Besides Andasol, FAUDI candle filters are also

used in Spain in the Extresol power stations 1 and 2.

10 | 11

Depending on requirements and the process used,

hydrocarbons from the feedstock products are cracked

and further treated in a reactor with a catalyst bed. If impurities

such as coke particles, rust or other metals are deposited in

the reactor, the whole process could be impacted. Influence

on the speed of the reaction, an increase in the differential

pressure, poor liquid distribution in the catalyser and, above

all, long downtimes for the expensive catalyst plant are

only some of the possible consequences. It is therefore

important to avoid these negative and costly effects. A high-

performance filtration system from FAUDI is the solution. And

there is a good reason for this: as a leading filter manufacturer,

FAUDI can look back on 70 years of company history that

includes many technical innovations and patents. Many oil

refinery operators therefore rely on FAUDI filter technology.

Sophisticated catalyser protection

FAUDI for BPCL

Technical Data

Medium: vacuum gas oil



Design pressure: 25 bar


Bharat Petroleum Corporation Limited (BPCL), one of India‘s

highest-turnover companies, puts it faith in modular filters

from Stadtallendorf. This range of modular filters is a system

designed to filter hydrocarbons and runs automatically,

almost maintenance-free and above all with no filter material

consumption. Cleaning is effected automatically, with the

candles in the filter being flushed in the reverse direction of

flow – without interruption to the filtration process. Thanks

to its modular design, large flow volumes can be handled.

It is also possible to extend the filter systems in a variable

way. This ensures that a customer-specific extension can be

added to the plant while keeping costs under control. BPCL

trusts the filters made by FAUDI and secures competitive

advantage for itself by reliably protecting the catalyst beds

from contamination and improving cycle times.

Inside Filtration – The Official FAUDI Newsletter

The fascinating inner-lifeof an ocean giant

FAUDI for Shell GmbH


Tankers fascinate people due to their huge size. It is not

apparent at first sight that in the interior of the giant ship

finely tuned and elaborate mechanisms must operate in

order for loading and unloading to be performed smoothly.

For example, in the final stage of unloading, large quantities

of air are fed through the pipes. This must be separated out

of the liquid flow before it passes the measuring devices.

Here, everything depends on the highest possible precision

and reliability of the technologies used. In its tankers, Shell

GmbH uses gas separators from FAUDI, which, in addition

to having approval by the weights and measures authorities,

guarantee the performance of the gas separation and also

require no maintenance. By constantly measuring the fill

level, the system prevents the level of liquid from sinking

to a critical point, and pressure blows can be intercepted.

Besides helping in the unloading of tankers, FAUDI gas

separators are used in many systems for transferring aviation

fuels, petrol and other hydrocarbons.

Technical Data

Design pressure: 25 bar



Air throughput: max. 2,200 m3/h

8 | 9

How can the exacting demands of a global player with 75

years of history be met - one which also happens to be

number one worldwide in the independent servicing of civil

aviation engines? MTU Aero Engines is one such company. It

develops, manufactures, services and repairs jet engines for

the civilian and military markets and has achieved a leading

position in this field of engineering. In addition to several

locations in Germany and a number of global partnerships,

MTU has had a manufacturing facility in Rzeszów in Poland

since the beginning of 2009. Two FAUDI vacuum filters are

used for the required processing of the cutting fluids for

two processing lines used to machine nickel-based alloys,

high-alloy steels and titanium. The floor-based systems

Global playerswelcome

FAUDI for MTU Aero Engines

Technical Data

Filter surface: 7.5 m2

Filtration grade: 30–50 μm

Feed quantity: 2100 l/min and 2200 l/min

Design pressure: 12 bar an WZM

Operating temperature of coolant: 22 °C

Container (steel): approx. 19,000 l

serve as the central units for supplying groups of machines

comprising six and four grinding machines respectively.

Filtration is effected using non-woven fleece in order to

achieve the required filtration grade of 30 μm. A control

system programmed by FAUDI ensures that all elements

and power units interact reliably with each other. In order to

guarantee the assured availability of its plant over the long

term, MTU puts its trust in the many years of experience

in planning, design and manufacturing that FAUDI can look

back on. The expertise and product quality of FAUDI GmbH

provides MTU Aero Engines with the basis for a successful

and dependable partnership.

Picture: MTU Aero Engines


Germany‘s second largest tyre manufacturer,

Continental AG, sees great potential in the South

East Asian region. As a result, the company decided to

set up a new production facility in Thailand. It has been

producing components for diesel fuel injection systems

there since the beginning of 2009. Continental ordered

two central coolant processing systems in order to set up

the new production operations. The „soft“ production area

is supplied by a FAUDI FUF 22 vacuum filter unit (main

filtration) and an AS 18 pre-coat filter unit (bypass filtration)

while the „hard“ production area is supplied by FAUDI

Type AS 34 twofold pre-coat filters (that can be extended

up to fourfold).

Parts made from cast metal are processed on the soft

milling machines. A FAUDI vacuum filter with relatively

high-quality filter fleece was chosen as the filtration

solution for the machining oil, which is required in filter

quality NAS 12. This ensures that high filtration quality and

Quality for any demandFAUDI for Continental, South-East Asia


a filtration grade of approx. 30 μm are achieved even with

new fleece, i.e. without filter cake. The pre-coat filter in the

bypass also prevents very fine particles from collecting in

the machining oil.

In hard machining, i.e. steel grinding, a low-viscosity

grinding oil with a very high filtration of contamination

class NAS 6 is required as coolant. The ideal solution here

is a pre-coat filter system made by FAUDI – the candle

filter allows deep-bed filtration and thus a high filtration

grade. The filter elements are also protected from lasting

contamination through the fact that a deposit layer

develops on the filter candles that is then cleanly removed

thanks to a specific difference in pressure. The dirt is then

finally discharged from the system in a so-called sludge

treatment process. Continental sees FAUDI GmbH as a

competent and reliable partner for whatever demands that

have to be met.

6 | 7

Eastern Europe is growing very rapidly as an automotive

region. Continental AG opened a new production facility

in Zvolen in the Slovak Republic in 2005 in order to keep

pace with this development and to retain its international

competitive edge. It is intending to expand the new factory

in Zloven to become one of the largest facilities for the

manufacturing and assembling of brake callipers. FAUDI

equipment is increasingly being used in the location‘s

16,000 square metre production area, e.g. a coolant cleaning

and supply plant with sediment tank and backflush filters.

This supplies 11 cutting machines with a total capacity of

8,000 l/min. The required filtration grade is 60 μm. In order

Clean performancefor a clean emulsion

FAUDI for Continental, Eastern Europe

to achieve this, the feed emulsion is first pre-cleaned in a

sediment tank and subsequently pumped through three self-

cleaning backflush filters. These are equipped with split-pipe

filter elements made from stainless steel and are backflushed

by the pressure in the system using clean emulsion. The

backflush liquid is then cleaned once more with a vacuum

filter. This combination of various filter systems ensures safe

supplies of clean emulsion to the machining equipment.

Continental AG has great expectations of its location in Zvolen

and puts its complete trust in products made by FAUDI.


The Austrian company Berndorf Band GmbH has been

manufacturing endless steel bands since the beginning of

the 20th century. A subsidiary of Berndorf AG, the company

takes stainless steel, carbon steel and titanium and turns

them into high-precision processing and conveyor belts.

This Austrian company has built up a reputation around the

world in the development and manufacture of endless steel

belts. The products developed and produced by Berndorf

Band GmbH can be found around the world, with exports

accounting for over 90 % of production.

Berndorf attaches great importance to the highest

precision in all areas of its work. Innovative and sustainable

solutions are also required when it comes to recycling

and disposing of the waste products that result from the

production process such as grinding slurry and swarf.

FAUDI provides Berndorf with such a solution in the form

Endless belts for projectsall over the world

Berndorf Band GmbH


Technical Data

Component: stainless steel belts

Processing: grinding, rolling

Coolant: emulsion

Type of swarf/slurry: broken swarf mats

Operational: 12 months/year22 working days/month24 hours/working day

Project volume: 355 kg/h

Residual content of coolant sludge:

approx. 55 % after pre-demoisturising extrusion230 kg/h

Residual content of coolant sludge:

approx. 30 %

Residual content of coolant briquette:

approx. 6 %

Briquette properties: Ø = 95 mmL = approx. 80 mmDensity = approx. 5.1 kg/dm3

of a hydraulic briquetting press. Waste materials that

contaminate the coolant during the grinding and rolling

stages are separated from the actual coolant using a

briquetting press and an extruder allowing the liquid to be

fed back into the coolant process.

The advantages can be seen in the distinct savings

in new coolant and also in the possibility of recycling the

filtered residues such as swarf, which are sold to waste

disposal companies. In addition to these advantages, the

high quality of FAUDI products and the volume reduction

result in a lower handling overhead.

The press, working 24 hours a day throughout the year

generally pays for itself within 18 months. It is therefore not

surprising that Berndorf relies on products made by FAUDI.

Picture: Berndorf Band GmbH

4 | 5

One of the world‘s largest oil companies, Brazil‘s Petrobas

S.A., uses filter units from FAUDI in its REVAP refinery.

The fully-automatic and maintenance-free FAUDI modular

pump units are used in refineries to filter hydrocarbons.

Low-molecular hydrocarbons, rust and metal residues are

produced during the cracking processes that take place

in the refineries; these can damage the catalyst units. In

order to prevent this, a cleaning process using modular filter

systems must take place. However, this results in medium

being lost through flushing as it has to be used for flushing,

or an external medium has to be used. By using gas-assisted

backflushing, a maximum amount of filtrate can be obtained

Maximum performance – minimum filtration loss

FAUDI for Petrobas

without losing the medium itself through flushing. It is

this technique that is used in FAUDI‘s modular filter units.

During cleaning, the individual modules are first flushed with

medium or external medium and a gas buffer is then fed into

the module. Medium flushing loss is reduced to a minimum

since the modules no longer need to be fully flushed with

medium or external medium. The inert gas used in the

backflushing process is separated from the medium using a

gas separator. Petrobas is a technological leader in offshore

production and puts its complete trust in FAUDI‘s high level

of technical expertise in order to maintain this position.



Contents

3 Using instinct and entrepreneurial thinking to become “Local Hero - Mutmacher der Nation”

4 Endless belts for projects all over the world

5 Maximum performance – minimum filtration loss

6 Quality for any demand

7 Clean performance for a clean emulsion

8 The fascinating inner-life of an ocean giant

9 Global players welcome

10 Protected solar power in Spain

11 Sophisticated catalyser protection

12 Clean sea water thanks to automatic backflush filter

2 | 3

Imprint

FAUDI GmbH

Scharnhorststrasse 7

35260 Stadtallendorf

Telefon +49 (0)64 28 702-0

Telefax +49 (0)64 28 702-188

[email protected]

www.faudi.de

Germany needs role models - people with optimism and

ideas that inspire. For this reason a top-class jury with

Lower Saxony‘s Premier, Christian Wulff, as patron awards

an annual prize to „Local Heroes - Mutmacher der Nation“.

The prize recognises entrepreneurs from small and medium-

sized companies who have shown exceptional and exemplary

entrepreneurial spirit and determination.

In 2008 Horst Watz, Managing Director of both WATZ

Hydraulik and FAUDI GmbH received the prize for an

outstanding entrepreneurial decision. In May 2006, Horst

Watz bought the insolvent FAUDI GmbH in Stadtallendorf.

The company, numbering 80 employees, was founded in 1938

and is one of Germany‘s traditional companies, operating in

the field of filtration technology. However, the once number

one address in the field of coolants and process engineering

got into great difficulties as a result of mismanagement and

the changing economic situation. Following the instigation

of insolvency proceedings, the company faced being sold

off and broken up. Competitors were already expressing

interest in the company‘s patent rights. Horst Watz decided


Using instinct and entrepreneurial thinking to become “Local Hero – Mutmacher der Nation”

Courage and gut feeling – a good combination

to purchase the company just 24 hours before the bidding

deadline expired. Through this decision – as he himself calls

it, a gut decision – he saved 80 jobs and a medium-sized

company with a long tradition. The purchase price of 1 million

euros was financed by his own company, WATZ Hydraulik

GmbH, with start-up financing of a further 3.5 million euros

being secured by private guarantees.

Horst Watz has not regretted his courage and his (gut)

decision. On the contrary: „At the end of the day it was a

question of a traditional German company and its people,“

relates the businessman. He continues, „Some people say

that such a decision requires courage. That may be. But I

just knew what the potential of the company and above

all of its people was.“ Insolvency is no longer an issue for

FAUDI. Turnover in 2007 amounted to eleven million euros

and increased significantly in 2008 to 14.5 million euros. The

number of employees has now grown to 85, including 12

vocational trainees who will all complete their training with

flying colours.

Far left: Horst Watz, “Local Hero – Mutmacher der Nation 2008”

The Official FAUDI Newsletter

Issue 1 / 2009 / www.faudi.de

Inside Filtration

Clean filtrationtechnology

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