Alcomex

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1. VIOD Invests in Enhanced Grinding Technology

   20/09/2023 09:04 Comments Off on VIOD Invests in Enhanced Grinding Technology

   

   VIOD is witnessing a substantial growth in the share of industrial springs, particularly in the domain of thick wire diameters exceeding 18mm. The evolving quality demands from customers necessitate a careful consideration of the appropriate technology that ensures both efficiency and cost savings.

   The older grinding technology, which VIOD has relied on for years and proven to be effective, is now being reevaluated due to changing market conditions and increased price competitiveness. Efficiencies in setup times, cycle times, and maintenance are crucial. This presents an excellent opportunity for VIOD to invest in new machines boasting significantly improved technology compared to their older counterparts. These advanced machines operate intelligently, allowing us to process more springs simultaneously or manufacture springs that other companies are incapable of producing.

   New Dry Grinding Machine with Advanced Programming Capabilities

   There is a specific demand for ground industrial compression springs. Last year, the grinding shop invested in a state-of-the-art dry grinding machine, the OMD MA-16 7000, to replace the outdated OMD MA-16 7000. The latter machine had been in use for 30 years and was still operating on MS-DOS control, limiting its programming capabilities. With the acquisition of the new machine, we now have the ability to create far more sophisticated programs. The ability to control the 2 grinding discs at varying speeds means that we no longer need to turn the springs over at the end of the cycle. Additionally, the refined technology in the new machine has led to a 60% reduction in grinding wheel consumption. The outdated hydraulic and pneumatic systems have been replaced by servo motors, allowing for much more precise and accurate programming.

   

   Introduction of the New Wet Grinding Machine

   Another wet grinder is set to be delivered to VIOD later this year, replacing the 2 old wet grinding machines that have been in service since the early 1970s. Once again, we have chosen an OMD machine—the OMD H-80. This new grinder enables us to grind springs with an outer diameter of up to 330mm, a significant improvement from the previous limit of 250mm. Moreover, this machine adopts the same user-friendly software philosophy as the other OMD grinding machines, facilitating smoother rotation of employees and enhancing their motivation to work with these new machines.

   In June 2023, we organized an on-site drivers’ meeting for the first time. Managing Director Lesjöfors Fjädrar AB Jan Carlson and Managing Director Lesjöfors Heavy Springs UK Micheal Gibbs were esteemed guests at VIOD. Based on the shared experiences during this meeting, it became evident that OMD is the preferred supplier of grinding machines. OMD’s superior price-quality ratio and excellent service ultimately surpass those offered by alternative manufacturers such as Dorn.

   Given the burgeoning demand for polished springs and the increasing competition from the Asian market, technology plays a crucial role in maintaining competitiveness. VIOD is enthusiastic about contributing to the growing demand for larger and thicker springs at our facility in Breukelen.

2. New Tension Springs Centre in Poland

   06/09/2023 15:51 Comments Off on New Tension Springs Centre in Poland

   Sales Forecast and Expansion Plans

   Since 2016, Alcomex has been growing its share in tension springs for residential doors. The Board of Alcomex Springs Group has prepared the sales forecast for years 2022-2025. Sales of tension springs are expected to quadruple in the coming years. Based on this projection, the decision was made to split the production of door springs in Marki into separate units for torsion and tension springs. To accommodate this growth, a new location was invested in to enable the production and assembly of tension springs.

   Lease Agreement and Conversion Works

   At the end of November, the Lease Agreement was signed for renting a 5320 square meters warehouse area and office area in a building with a total area of approximately 38500 square meters. The building, known as ‘Hall B’, is located in Marki, just 500m away from our current location. The early access to the new facility was granted from 01.02.2023. From that time, all necessary works must be done to convert the warehouse area into a primarily production area for tension springs.

   Conversion Works Details

   The conversion works involve various tasks, including:

   1. Extension of the main electrical switchboard according to Alcomex energy requirements.

   2. Installation of proper lighting in the production area up to 500 lux.

   3. Delivery and installation of 14 skylights with ventilation function, a weather control unit, and a necessary sprinkler system.

   4. Construction of new forklift charging stations equipped with gas detection and sprinkler system.

   5. Installation of radiant heaters to create a comfortable working environment.

   6. Conversion of existing office rooms into changing rooms and social areas.

   Completion of Adaptation Works

   In mid-May, all fit-out works were completed, and all necessary notifications, agreements, and approvals from relevant authorities were obtained. As a result, on 29.05.2023, the Protocol of Completion of Adaptation Works was signed. With this milestone achieved, additional tasks such as the installation of the piping air system and the transfer of two air compressors from Hall D could begin. Furthermore, all necessary equipment, including lockers, benches for changing rooms, office furniture, desks, printers, and kitchen equipment, were purchased to provide a comfortable environment for our employees during breaks.

   

   Cooperation with Czech Republic and Equipment Transfer

   In addition to the expansion in Poland, we have initiated closer cooperation with our colleagues from the Czech Republic, as some production will be transferred from there. The first training session took place in Brno, where our employees familiarized themselves with the production process for tension springs, which will be transferred to our new center.

   Operational Timeline and Customer Deliveries

   The transfer of the current production equipment to the new center is scheduled for mid-June, followed by the transfer of additional machines and tooling equipment from the Czech Republic in July. Our goal is to have the new tension spring center in Poland fully operational from the first of September this year, enabling us to deliver our products (springs) to customers all over Europe.

3. Constant Force Spring: Technical Advantages

   09/08/2023 16:40 Comments Off on Constant Force Spring: Technical Advantages

   Our know-how in the field of Constant Force Spring dates back to the beginning of the 20^th century.

   At Alcomex Springs, we are proud to offer our expertise in the constant force spring, a mechanism that provides a multitude of technical advantages. This innovative solution is more compact and lighter than most other methods of return or retraction, making it an ideal choice for many industries.The constant force spring is designed to provide a smooth and constant load over its entire length of travel, eliminating the need for deadweights, linkages, cylinders, and other systems. This feature alone can significantly decrease the size and cost of devices, making it an attractive option for manufacturers looking to optimize their products.

   Our constant force springs and assemblies are used in countless applications across various industries. For instance, in the aeronautics industry, we develop Jet and cargo door opening and closing assistance systems, which are critical for ensuring the safety and efficiency of air travel.

   

   In the green energy sector, we are actively working on cable retraction assistance solutions for electric vehicle chargers, enabling more convenient and efficient charging for electric vehicles. We also provide solutions for the POS, defense, equipment, and health industries, among others.

   One of the reasons we differentiate ourselves from our competitors is our ability to produce custom springs and sub-assemblies tailored to meet our clients’ specific needs. Our team of experts is always ready to collaborate with clients, providing guidance and support in developing innovative solutions that exceed their expectations.

   In conclusion, the constant force spring is a versatile and reliable mechanism with many technical advantages that can improve the performance and efficiency of devices across various industries. At Alcomex Springs, we are committed to delivering innovative solutions and outstanding customer service. Contact us today to learn more about how we can help bring your projects to life.

4. Production monitoring at Alcomex Spring Works

   09/07/2023 10:53 Comments Off on Production monitoring at Alcomex Spring Works

   In the Alcomex Springs Group, we are continuously looking at ways to improve our production performance and efficiency, to exceed the expectations of our customers through operational excellence. As an example of that ambition, last year we successfully completed a pilot project for monitoring machine performance by applying the ‘Act-in MES’-system at Alcomex Springs Works in the Czech Republic. The goal was to get to know and test the possibilities of the offered system and its suitability for our type of production. As part of the pilot, two production machines (FUL36 and FUL46) were connected, allowing these to send information about status (in operation or not working), the number of pieces produced and the number of non-conforming products. These data are transmitted over the internal network to the core of the system, which allows us to monitor in real time the status of individual production orders on these machines.

   

   

   The core of the system consists of several interconnected modules. The “Production Scheduler” module is used for detailed planning of production orders. Individual production orders are loaded directly from our ABRA information system and assigned to the production plan for each machine, using a simple Drag & Drop functionality. This tool allows planners to monitor the workload of individual workplaces and, thanks to the online connection with the given machine, determine the expected end of production. Planned jobs are subsequently displayed on the operator panel directly at the individual machines.

   Another integral part is the “Performance Monitoring” module, for online monitoring of the utilization and condition of machines, their effective use according to the OEE indicator, the progress of orders and the work of operators. The key to this module is the on-line connection of machines to the system through which we can monitor in real time the start and ends of downtime, the cause, production cycles, production speed and the number of approved and non-approved products, including the causes of discrepancies.

   Part of the installed package is an operator panel (one for both machines), which is used to log in to exchange or enter information regarding the progress of individual orders.

   

   Implementation Progress and Expected Benefit

   As part of this pilot project, the suitability of this software for our type of production has been verified, and our comments and software modifications are currently being implemented to allow us to apply this system to more of our machines. Meanwhile, preparations for automatic booking of performances on individual machines are in progress and the commissioning of visualization screens in the production areas is also part of the implementation.We are convinced that this tool will allow us to improve the quality of the production processes within Alcomex. Also, thanks to the visibility of each individual production indicator, we will increase awareness and involvement of Alcomex production people in continuous improvement of our operation. In the end, our loyal customers worldwide will profit from this upgraded production performance.

5. HZ Solutions is preparing for the future, opting for reliability and efficiency with a new deburring and polishing machine from Rösler.

   24/04/2023 15:54 Comments Off on HZ Solutions is preparing for the future, opting for reliability and efficiency with a new deburring and polishing machine from Rösler.

   

   HZ Solutions b.v. is a company based in the south of the Netherlands, in Hilvarenbeek. HZ Solutions specialises in developing spring and fastening solutions for customers. This means helping the customer by developing new solutions to their problems and providing custom solutions. The products developed by HZ Solutions, such as wire, die-cutting and fastening products, are produced in-house from the drawing board using extensive technical knowledge and experience. To serve customers well, it is vital that HZ Solutions has the right technology and is ready for the future.

   To ensure they stay up-to-date with the latest technologies, HZ Solutions decided to replace their rotary vibrating deburring machine from Rösler. This machine has been in use for a long time, but could no longer operate independently due to the increasing volume of deburring work. It was therefore necessary to invest in a new machine.

   After careful research and comparison, HZ Solutions again chose a machine from the Rösler brand. The existing machine has been overhauled and prepared for the future. By investing in both the existing and a new deburring/polishing machine, capacity has been greatly expanded. This allows HZ Solutions to continue to support customers in developing new solutions. To automate the process as much as possible, a conveyor belt was also installed between the deburring/polishing machine and the dryer. This allows products to be transported automatically. See attached drawing and photos.

   Besides promoting work capacity, HZ Solutions has also paid due attention to creating a safer working environment for their employees. For instance, lids have been fitted to reduce dust emissions and noise levels as much as possible. And investments were made in an extraction system for both the new deburring area and the post-treatment areas. This extraction will extract the remaining dust, vapour and smoke as much as possible, as well as the paint fumes and welding fumes in the heat treatment room. Through these measures, HZ Solutions has facilitated better working conditions. 

   

   

   

   Deburring and polishing plant is installed.

   We are very pleased that the new deburring and polishing plant is now installed. Below you will find some technical data of the new Rösler deburring/polishing machine type R 125 EC and the Naaykens extractor series 510, type B:

   Rösler deburring/polishing machine type R 125 EC:

   –     extremely hard-wearing, hot-moulded Rösler polyurethane coating, allowing HZ to produce trouble-free for years without additional maintenance costs

   –     manual separation slide, ensures damage-free separation, even for sensitive products

   –     in combination with the quickly removable separator slide, EC-type deburring machines are more universal

   –     more flexible use than machines with a permanently installed separation flap, also allowing larger products to be handled

   Naaykens extractor series 510, type B:

   –         direct drive. Impeller mounted on motor shaft.

   –         suction-only centrifugal fan

   –         vertical discharge via various filters

   –         extraction capacity: 2,600 m³/h

   –         noise level: 49 dB(A)

   Paint vapour & weld fume extraction:

   –         working range: 2 m, diameter extraction arm 160 mm

   –         extraction capacity: 850 m³/h

   –         noise level: 67 dB(A)

   –         HEPA filters allow the filtered warm air to be blown back into the room, preventing heat loss in the room

   For more information about HZ Solutions, please refer to our website: www.hzsolutions.com

6. Manufacturing expansion in Alcomex India will also supply the US door spring market

   21/03/2023 14:46 Comments Off on Manufacturing expansion in Alcomex India will also supply the US door spring market

   

   Alcomex will supply in the US (United States of America)

   In the US, almost every American house has a garage. Therefore, the market for residential overhead garage doors is enormous in this continent. Together with an increasing demand for overhead doors from the industrial building sector, the American door spring market is about four times larger than in Europe. This is an opportunity that Alcomex will make good use of. Alcomex India will supply doorsprings in the US.

   The manufacture of door springs is an important expertise that the Alcomex Group holds. Alcomex is manufacturing both standardized and customized torsion and tension door springs. The custom-made door springs are manufactured in the Dutch city of Opmeer and Marki, Poland.

   

   Standard door spring production 

   Since 2008 Alcomex has manufactured standardized door springs in Pune, India, where the Indian subsidiary owns a 10,000 square meter industrial site. Most of the produced volume is exported to Europe. The Indian factory has experienced constant growth since the start and annually, producing approximately one third of our global volume of door springs. The facility employs about 90 highly skilled workers who work in two-shift.

   

   New production line and warehouse

   Alcomex has made a major investment in India to expand the manufacturing and warehouse in order to take advantage of the potential in the US market. In the second quarter of 2023, a new production line will be taken into use. There will be new coiling and shaping & assembly machines as well as lines for painting, powder coating, printing and waxing to mention a few of the new machinery and equipment. At the end of the year, a new-built warehouse of 2,500 square meters is also ready to stock the door springs before shipping. The expansion will of course bring many new job opportunities.

   

   Jelle van Vliet & Conrad Hietink, MD’s of Alcomex comment on the investments:

   The size of the investment in India is about 1.9 MEUR and will more than double our capacity, opening the way for a successful entry in the North American market.

7. Word from a client: Aseco

   03/01/2023 15:00 Comments Off on Word from a client: Aseco

   

   The sustainable disassemblement of cargo ships

   A look inside the process

   Freighters have a long durability. They can be used for decades before needing replacement. But even for these huge vessels there comes a time when they’re put out of commission. Getting rid of tons of steel is however no easy job. They’re often dumped and get washed ashore. Frank Geerdink, Director of Aseco Europe B.V, found a sustainable solution for this problem. 

   To make this project possible, Aseco has collaborated with CMT.  In the CMT shipyard decommissioned ships are cut up in different parts by using huge cutting wires. At the end of this extensive process, all that is left are big slices of metal. Some of these parts can be molten into steel, others get turned into recycled products. Aseco even manages to produce energy from some leftovers!

   They main advantages of disassembling ships in such a manner:

   • It’s a 100% save; for the surrounding environment, nature and people. 
   • It reduces Co2 and also reduces air and water pollution.
   • A safe environment can be created without having to disassemble a ship directly in the ocean (which often leads to pollution). 
   • It’s an automated system that doesn’t require hard and physical labour from workers. 

   Are you curious about this disassemblement process? Check the video below.

   https://vimeo.com/728589256

   The challenge 

   enthusiasm by the team. Sustainability is an important pillar for Alcomex. So having the opportunity to collaborate with Aseco on such an important project fits perfectly with Alcomex. 

   Aseco required very specific pressure springs to place in between large steel pearls. The mechanical process could not function without these springs. They also needed to be dirt resistant in order to make the disassembling process economically viable. And to be able to cut straight through freighters the springs had to be especially strong. Such a complex project requires a custom solution; a service that Alcomex offers. 

   Before the project could be launched, Aseco and CMT international required approval and subsidies. Due to the complexity of the project it took several years before all requirements were met. Luckily in 2022, approval was given and they could finally start. 

   The solution 

   Before Alcomex could start their production process, a couple of NDA’s needed to be signed. Because the project was still in its first stage, confidentiality had to be assured. After signing however, Alcomex started manufacturing the specific springs required by Aseco. By installing the springs within a certain distance of one another, it was possible to cut through the ships. 

   Frank Geerdink, Director of Aseco about Alcomex. 

   The deciding factor to work with Alcomex was their way of communication. They understood in rapid time what we needed in order to run our first tests. The fact that they were able to custom make the products that we needed, exactly at the right time, is even further proof that we choose the right company to work with. 

   Are the Alcomex Springs important? Without a doubt! Even though 5 other businesses sent their springs for testing, the clear and concrete manner of communicating by Alcomex was by far superior.

   

8. Alcomex expands its e-commerce product range by 900 new standard stock springs

   29/11/2022 10:17 Comments Off on Alcomex expands its e-commerce product range by 900 new standard stock springs

   Alcomex is always working on providing a better service to its customers. Not only when we are directly in contact, but also online. We work hard to continuously improve our e-commerce experience. Not only for a better customer journey in our web shop, but also to provide a better and larger product range online. Alcomex has become part of the Lesjofors Group. This partnership brings us a lot of opportunities and synergy projects. The first synergy project is the addition of 900 standard stock springs in our online shop.

   

   Which new standard springs are we adding?

   We are expanding our web shop assortment with more than 900 new products in the following categories:

   • Conical compression springs,
   • Vibrator springs,
   • Extension springs with turnable loops,
   • Thread fittings,
   • Double torsion springs,
   • Lockwashers Type A,
   • Lockwashers Type B,
   • Lockwashers Type C

   Moreover, we are also adding a great number of new products to our already existing torsion and disc springs assortment. With these improvements within our product range, we can provide our private and business customers an even better applicable spring for their application.

   

   

   An optimal user experience

   To ensure that our ordering process online is as easy as can be, we have added two new functionalities in our e-commerce platform.

   Pay on account (for businesses)

   As of now it is possible for business customers (with or without an account) to pay on account. By doing so your organization will receive the products even faster than before.

   

   No results? Get a custom made spring

   Are you looking for the right spring within your application, but are there no results? No problem. You now can easily create a custom made springs order via a form in our web shop. By filling the form out you will get in contact with our sales engineering team who will help you in the process of creating the right spring for your application.

   

   By expanding our product portfolio to almost 5.000 springs – which we can deliver directly from stock – and providing a better online customer journey. We strive to fulfil an ever-rising online demand for industrial springs with the best possible quality and a high level of service.

9. Spring-in-spring – optimal tension springs for garage doors

   24/11/2022 15:40 Comments Off on Spring-in-spring – optimal tension springs for garage doors

   

   Customer case: ConDoor

   Springs are a vital part of the perceived quality of a sectional overhead garage door. If door springs are not well balanced, the door does not run smoothly. Spring technology is a complex part of the sectional overhead garage door and a combination of factors determine the quality, life span and functioning of a spring.

   A fruitful partnership

   Alcomex, part of the Lesjöfors’ Group is a highly specialized leading supplier to the door spring market in Europe. One of Alcomex’s customers is Condoor, a major producer of insulated overhead doors for industrial and residential buildings producing more than 50,000 doors per year. Since 2017, Alcomex is the sole supplier of door springs to the company after a process of investigating, bench-marking and testing of Alcomex’s solutions. 

   

   Kees-Jan Honig, CEO of ConDoor, comments on the test process:

   “After running a severe testing program in our own lab, we started producing small batches of doors with Alcomex springs. When all the lights turned green in 2017, we took the next step and Alcomex became our sole supplying partner in springs. Which means that we are 100% relying on their operational excellence performance. Also our customers, the door dealers that install the door at the homeowner or industrial facility, were happy with the new quality, life span and balance as well.” 

   Innovative spring solution revolutionized the business

   Condoor is impressed by Alcomex innovative approach. Alcomex introduced a Quattro tension spring solution which brought many benefits to the table for Condoor. Earlier, tension springs were perceived as the lesser solution in the garage door business. 

   Kees-Jan Honig explains:

   “Torsion springs could be calculated exactly to the right door weight and lifting system and with tension springs people always claimed that you had to compromise on this. The Quattro system proved to be perfect for our residential doors. Thanks to the spring-in-spring solution, the system was able to comply with the tough European safety norms. Also, the construction of the spring sets proved to be very compact, using little build-in space, which made it possible for us to offer pre-tensioned hardware sets to our customers, saving them time and money on site. The next step was the availability of that system for higher door weights, meaning bigger garage doors. Nobody wants to go back to the more complex and expensive old solution now.”

   

   

   Long-term relationship

   Condoor’s experience is that it is better to develop a relationship with a supplier to a level that both parties benefit from, rather than switching frequently. A speaking example of flexibility is the direct supply that Alcomex organized from its’ factory in India to Condoor’s plants in the Netherlands.

   “Both parties have to make money and on both sides there are people working to do their utmost. But people make mistakes sometimes and for us, it is important that problems are solved without any hesitation and that our supplying partner can follow our growth. In Alcomex, we have a partner with good logistic performance, high-quality product with ongoing development and a team of people that seem to realize what we need every day”, says Kees-Jan Honig.

10. A special edition of our Wired Magazine: 30 years Alcomex. Read it now!

    23/11/2022 09:54 Comments Off on A special edition of our Wired Magazine: 30 years Alcomex. Read it now!

    

    Exceeding expectations, the foundation for the success of Alcomex.

    In the latest edition of our Wired Magazine, we proudly look back on our 30 year history. Alcomex excisis 30 years and a lot has happened.

    For us the aim is that, while we are looking back with pride to our 30-year company history, we do realize that the secret of our success should be the ongoing ambition to live up to customer expectations and, on each new day, try to even improve our performance. 30 years of growth is a great achievement, but it means nothing if tomorrow we disappoint one of our customers. For example, by late delivery, bad quality, non-competitive pricing, or a failing customer service.

    That is the reason why we have now taken the opportunity to reload the Alcomex brand, by renewing our company values, mission, vision, and culture. We would like to be known, now and in the future, as the company that always tries to exceed the expectations of customers, suppliers, employees, shareholders, and local communities. While considering the impact we have on the planet we all live on. That is quite a big ambition and a major challenge. But we do know that the secret of our success lies in working with happy customers and in life-long partnerships.

    “We would like to be known, now and in the future, as the company that always tries to exceed the expectations of customers, suppliers, employees, shareholders, and local communities. While considering the impact we have on the planet we all live on.”

    Alcomex going strong for 30 years

    So far, the growth of Alcomex Springs Group is above expectation. Who would have thought that we could supply door springs to the US-market? Now we do, in large quantities. We can do this thanks to a strategic decision we took 15 years ago, with the start of our presence in India. Alcomex is in a good position for further growth. This is based upon a rapidly growing e-commerce platform, significant investments in machinery and facilities, and the new people that have reinforced our international teams.

    Pyramide of succes

    Our strategy is strongly connected to the five ‘securities’ in our Pyramid of Success,  a business model that we apply consistently for a number of years now; product quality, reliability, the right price, flexibility, and innovative technical solutions. Each and every decision is taken by evaluating it against the background of these basic check points. This for us ensures that we always try to take a direction that is beneficial for our main stakeholder: the customer.

    Wired

    Wired is our magazine through which we update our employees, customers, and other stakeholders with important developments within Alcomex Springs Group. We share stories and we open the dialogue for ideas and exchange of views.

    Take your time to scroll through the eight pages below and discover all you want to know about our mission, vision, core values, and listen to what our partners and customers have to say. And more…