USER REPORT: 2-component parts for the automobile industry

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  • Company: Denk Kunststoff Technik GmbH, Germany
  • Process: injection moulding, incl. 2-component parts
  • Application: automotive

Denk Kunststoff Technik was established 20 years ago. In 2009 the company, managed by the two brothers Falk and Lars Denk, moved to its present location in Gevelsberg. It now has a workforce of 80 and realized 15.5 million Euros in sales in 2014. Since the beginning of 2015, Denk Kunststoff Technik has now also been operating a facility in Nanjing, China, where 5 associates produce parts on 3 injection molding machines.

Annual sales growth of about 15%

The company’s customer base consists almost exclusively of well-known automotive suppliers in Germany, North America, China, Spain, the Czech Republic and Romania. In recent years, the company achieve an annual growth in sales of about 15%. The company’s technologically complex products include 2-component parts such as door check housings, plastic parts with metal inserts, plastic hinges, parts for the engine compartment, among others.

Mold making capabilities and specialized machinery

An in-house mold making shop, capable of producing basically any required mold, and an in-house mechanical engineering department to make specialized machinery ensure complete internal system integration within the company. Lars Denk sees his company as an “early follower” able to adapt complex processes quickly. For both Falk and Lars Denk, it is important to find the best process for every application.

Automation also designed in-house

In addition to in-house mold making and mechanical engineering of special machinery, automation is also designed in-house. Jointed-arm robots are used almost exclusively. Interim process steps such as welding are also implemented in-house at Denk. Product development is project-related. Application technology with the objective of continuous process development and improvement plays a vital part at this company.

As an automotive supplier, the company must give top priority to the quality of its products and processes. Denk is certified according to DIN ISO 9001 and VDA 6.1. ISO/TS 16949 certification is planned for 2016.

Energy efficiency as a focus

In this respect, the two brothers are enthusiastic about the EcoPower 300/1330 delivered by Wittmann Battenfeld at the beginning of March 2014. Lars Denk comments: “This machine consumes next to no electricity and operates with an extremely low noise level and high precision as well. That was something we could not have imagined before.“ Falk Denk finds the KERS system (Kinetic Energy Recovery System) of the EcoPower particularly impressive, since it enables recovery of the released braking energy for re-use within the machine.

In addition to the energy efficiency and precision, reliability and a long service life are important features for Falk and Lars Denk. On this account, the machines of Wittmann Battenfeld has already proved its competence with a hydraulic HM machine with 150 tons clamping force delivered to Denk ten years ago and equipped with an automation system, which is still in operation today, and a rotary table machine from the VM series with 110 tons clamping force.

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