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From simple factory to industrial production
The sandwich elements, as well as FrameTec and ProfileTec, can be applied in different locations in a building.

From simple factory to industrial production

Firm celebrates 40 years and invests heavily in production process

Sandwich elements are not necessarily the first thing that comes to mind when it comes to windows and doors. The applications do not stand out, but they do provide improved thermal and acoustic insulation. Stadur Produktions GmbH & Co. KG has successfully specialized in the production and sale of sandwich elements for more than 30 years. The company from Hammah, Germany, celebrated its 40th anniversary this year and also recently invested in new machinery, moving from a simple factory to industrial production.

Stadur Produktions GmbH & Co. was founded in 1982, when Wolfgang Sylvester started a trade in insulation materials. Even today, together with his son Marc, he still keeps a firm grip on the reins. "Stadur has a strong reputation when it comes to the production of sandwich elements. In 1995, a first large production hall was built for this purpose on the current site, followed by a warehouse with an area of about 4,000 m²," explains general sales manager construction Thomas Lütje. "This increased our capacity and allowed us to keep sandwich elements in stock for faster delivery. Today, the site features an office building, which also serves as a showroom, and five production halls. The current production capacity for standard plates is 5,000 to 6,000 m² per day."

STADUR4 FrameTec
The F&P product group - FrameTec and ProfileTec - has the greatest growth potential.

High quality plastic

Each sandwich element consists of a core of extruded polystyrene and top layer, available in different materials and thicknesses. With Stadurlon, developed in cooperation with BASF of Ludwigshafen, the manufacturer makes the difference. This top layer is extruded at Stadur Composite GmbH & Co. KG in Karstädt, after which the thin sheets are used at Hammah to produce sandwich elements. 

"With Stadurlon, one can give free rein to one's creativity. In addition to classic white, one can choose from a wide range of RAL colors, a film finish or an embossed surface," Lütje continues. "Bendable elements can be produced or panels with fireproof, acoustic or burglar-resistant properties. Stadurlon can also be replaced as a top layer with PVC, aluminum, glass fiber reinforced plastic (GRP), wood fiberboard, tempered safety glass, plywood or fiber cement."

STADUR2 fb concept
With Stadurlon, developed in cooperation with BASF of Ludwigshafen, the manufacturer is making a difference.

Successful transformation

To continue to ensure high quality, increase capacity and meet the shortage of technically skilled labor, Stadur invested heavily in its production facilities. Automation was implemented where it made sense, but still much of the production process must be done manually. 

"Two systems stand out immediately. We installed a new system for sorting the Renolit and other decors and an automated production line, which was custom-made and completely tailored to our needs. Together with the machine builder, we first determined the optimal workflow and looked at how the system would achieve its highest efficiency," says Marc Nickel, construction sales manager for Germany and the Benelux countries. "This machine is unique. Therefore, there were no reference projects. In the end, thanks to these investments, we made the step from a simple factory to industrial production."

Focus on sustainability

Today Stadur analyzes the logistics flow on the shop floor to produce even more efficiently and reduce delivery times even further. In addition, sustainability takes center stage. "For example, the trimmings from our sandwich panels are pressed into briquettes and sold as a source of energy, and we only use 100 % of recycled material to produce Stadurlon," Lütje and Nickel conclude. "About 30 % of the electricity consumed at the Hammah plant is self-generated. We have installed a total of 1,300 solar panels for this purpose in recent years. And for employees with electric cars, eight charging points were provided."    

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