We gladly welcome our visitors at our booth R51 in hall 6! Let’s talk about the latest trends and development in a pulsating market.
JEC World 2018
Composites are deeply embedded in the biggest markets of the economically strongest industries such as automotive, construction, aviation and renewable energies. You could call it a dynamically growing branch that conquers more and more industrial areas. Especially glass fibres continue to gain ground. About 95 per cent of all manufactured composites consist of this material. It is light, weather-resistant, has a high inherent strength and various surface textures. But also other composites like carbon fibre are used in many applications. In order to keep the overview over the diverse possibilities and to find new approaches for their own production, composites manufacturers need a platform for and with the sector’s experts.
The JEC World is exactly this meeting point. It is the largest and most important trade fair solely focusing on composites. More than 40 000 visitors consist of end-user-companies and stakeholders of the composite industries from all over the world. During conferences and innovations platforms, the participants can exchange views about the latest trends and developments.
We supply the composites market with renowned on-line measurement and control solutions for thickness, basis weight, density, coating add-on, and moisture.
The traversing quality control system Qualiscan QMS is the perfect tool for the demanding manufacturer. It offers non-nuclear sensors plus responsive, professional technical support, and the most reliable, well-built scanning platforms in the industry.
The Qualiscan QMS is a modular system for measuring, logging and controlling critical process parameters over the entire width of the product, including basis weight, coating weight, thickness, moisture etc.
The Qualiscan QMS can be used in virtually every industrial sector in which products are produced as a web, or where they are finished (laminated, coated, etc.). The versatile sensors and measuring devices of the Qualiscan QMS series can sense, log and continuously control such parameters as basis weight (weight per unit area), coating weight, thickness and moisture in a variety of web-type products.
The Qualiscan QMS is a modular system consisting of multiple measuring sensors and traversing frames acting as intelligent nodes on a network. The individual components are linked through a normal Ethernet cable as found in any office for networking multiple PCs.
Modern construction with intelligent sensors and traversing frames
Based on industry standard hardened computers
running Windows embedded operating system
Components communicate through digital interfaces
Savings in raw materials and/or energy at the manufacturing stage
Uninterrupted monitoring and logging of actual product quality
Improvement in product quality, especially in conjunction with control
After three and a half educational but also demanding years, now it was time: six industrial trainees of Mahlo GmbH + Co. KG received their certificates for their completed apprenticeship. Each young skilled worker will stay with the machine manufacturer from Saal.
“That feels great!” The proud graduates are on the same page, when Mahlo CEO Rainer Mestermann handed over the diplomas of the relevant Chamber of Industry and Commerce. Mestermann congratulated Ralph Bauer, Britta Eichenseer, Valentin Kaufmann, Dominik Roithmayr, Robin Schlögl und Maurice Sinzinger warmly: „Be proud of what you have achieved here.“ He also added some motivational words for his employees: “Now you can really through yourselves into the task! That is the best prerequisite for a successful career.”
CEO Rainer Mestermann and Instructor Andreas Beil
Getting started and focusing on the dream job that is what the recent industrial mechanics, mechatronics engineers, and electronics technicians are looking forward to after their dual apprenticeship with practical training at the company and theoretical lessons at the vocational school. Because every one of the six is sure, he or she has made the right career choice. That all ex-trainees remain loyal to their company pleases Mestermann: “It is a signal for us that we are doing a good job with supporting young talents. As a family-owned business that’s extremely important to us.”
Trainee Emma Thaler visits Britain’s capital for further education
Expanding your knowledge, improving your English language skills, and thereby discovering one of the most exciting European metropolises? What an opportunity! One that our commercial apprentice Emma Thaler seized by taking part in an advanced training at the Central College London that was organized by the vocational school Kelheim. For three weeks she learned new things about the United Kingdom’s economy, culture and language. After class, Emma had enough time to discover the British capital.
Mahlo supported her project, because the machine builder trusts the words of American politician Benjamin Franklin: “An investment in knowledge always pays the best interest.”
Welcome to the UK!
On 24 November 2017, my three week journey to London started. The preceding days, when packing my bag, I was pretty nervous and excited. I was curious what would lie ahead and what kind of people I would meet. I also have never been away from home for such a long time. But as soon as a arrived at the Munich airport and boarded the plane, all nerves were gone and I just wanted to get started.
Just after we had arrived in London, we were introduced to our host families. I was extremely lucky with mine. Hardly have I met people that nice and lovable. That’s why I felt at home from the first minute on.
The following days, the other students – all from the Kelheim and Regensburg area – and I had just one thing on our list until our class began: lots and lots of sightseeing. We walked through London all day long and visited many tourist attractions, for example the Tower of London, the Buckingham Palace and Camden Market.
When the first day at the College came, I was a little bit nervous what to expect, because I have never been to one. My nervousness was unfounded, however: our group consisted of many nice people and our teacher was also friendly. The following days and weeks therefore flew by. Due to our lessons and many interesting study trips, like a boot tour on the Thames to Greenwich or a visit to the court, we have learned a lot about England’s economy, language and culture. Our course also encompassed many presentations and a test.
Every day after class, we had enough time to discover London on our own. We did many funny things like ice skating, visiting the skyscraper The Shard (you have a stunning view of London) or the Winter Wonderland Christmas market and fairground at Hyde Park.
When we had to say our good-byes on 15 December at the airport, not one of us really wanted to leave. We had loved to stay a little bit longer but unfortunately that was not possible.
Now, that my journey is over, I can say that the three weeks passed by way to fast. London is a great city with beautiful places and interesting people. I have found many new friends and gathered experiences. For me, the trip was definitely worth it. Not just because I gained new knowledge but first and foremost because I developed myself. I can only advise everyone to seize such an opportunity when offered. And I also thank my employer that he made my extra-curricular training possible.
Industrial mechanic Tobias Hierl on his first weeks of training.
On 1 September, Tobias has started his apprenticeship as an industrial mechanic for machinery and plant engineering at our company. After three months, he has gained an impression of its future profession and already learned a lot.
It was always a given for me that I am going to learn a technical profession. Both my father and brother work and manufacture timber products, I wanted to do the same with metal. When our instructor Mr. Beil presented the apprenticeship as an industrial mechanics in the course of an orientation day, I was sure: this is it! The field of duty sounded pretty interesting. So I submitted my application to Mahlo and started here in September after finishing my ‘Mittlere Reife’.
Let’s get started
In the training workshop, all of us apprentices were allowed to work hands-on right from the beginning. For example, we have learned to cut workpieces to size, file and mill them. You should therefore have a certain degree of skill if you decide to become an industrial mechanic. Equally important are commitment and stamina. Filing for a longer stretch is more exhausting than you might think. When milling, you have to really concentrate to get the desired outcome. But this is also what I really enjoy. That and of course the companionship with my colleagues. We are six first-year industrial trainees and we get all along really well. In addition to that, you can always ask the older apprentices for help. The same goes for our instructors. No matter if it is about praxis or study matter.
Of course I sometimes think about what I want to do after my apprenticeship. I definitely want to educate myself further. Mahlo offers several options here. Prerequisite for that is a successful training as well as a good degree from vocational school. So far, vocational school is very diverse, interesting and funny. I especially enjoy the subjects Maintenance, Components and Production Technology. You just know, you later will use what you have learned now. That’s probably why it is more interesting.
I for sure am looking forward to the coming years of my apprenticeship and am curious what will happen next.
SAAL.Der italienische Edelschneider Zegna zählt zu ihren Abnehmern genauso wie das deutsche Textilunternehmen Trigema: Ein bisschen Stolz schwingt mit, als Ralph Greenwood-Mahlo und Rainer Mestermann, die Chefs des Saaler Maschinenbauers Mahlo, ihre bekanntesten Kunden aufzählen. Denn ohne die bahnbrechenden Produkte Made in Niederbayern täte sich die Mode- und Textilindustrie heute schwer, hochwertige Stoffe oder High-Tech-Gewebe herzustellen. Aber auch Papier- und Kunststoffhersteller, bei denen es auf eine exakte Produktion ankommt, sind brennend interessiert an den Lösungen von Mahlo.
Ralph Greenwood-Mahlo, der Enkel des Firmengründers Heinz Mahlo, und Geschäftsführer Rainer Mestermann erklären im Gespräch mit unserem Medienhaus: „Wir sind die Spezialisten für Messen, Regulieren und Automatisieren für alles, was sich auf Bahnen aufwickeln lässt.“ Ob bei der Produktion von Stoffen für Jeans, für Hemden, für Teppiche oder für Auto-Sitzbezüge: Die sogenannten Schussfäden der Textilien müssen schnurgerade sein. Aber auch das Gewicht muss exakt stimmen und die Feuchtigkeit darf nicht zu hoch sein. Sonst leidet die Qualität oder es wird Material vergeudet.
Hier kommt die Technik von Mahlo ins Spiel. Die Sensoriksysteme überwachen jede Sekunde den Fertigungsprozess – etwa beim Veredeln eines Stoffes. Bei Bedarf greift ein Korrektursystem ein und zieht die Fäden gerade. Eines der wichtigsten Produkte von Mahlo – die klassische Richtmaschine – basiert übrigens immer noch auf den Erfindungen des Firmengründers Heinz Mahlo aus den 50er Jahren, wie sein Enkel erklärt.
Ausgeklügelte Sensoren steuern Maschinen nach
Ohne die Richtmaschinen aus Saal hätten Textilfabrikanten ein großes Problem. Denn dann müssten sie alle paar Stunden mit einer Qualitätsprobe ins Labor, erläutern die Mahlo-Chefs. Erst dann könnten sie bei Fehlern die Produktion korrigieren. Schlimmstenfalls hätte die Maschine bis dahin Ausschussware produziert. Die Produkte von Mahlo dagegen kontrollieren ständig mit ausgeklügelten Sensoren die Qualität und steuern die Maschine nach. Am Schluss kann der Kunde dank der hauseigenen Anwendungs- und Visualisierungssoftware alle Produktionsdaten auswerten und die komplette Fertigung nachvollziehen – sowie die Qualität dokumentieren.
Vom einzelnen Zahnrad bis zur Software
210 Mitarbeiter stellen in Saal die Spezialmaschinen her. Stolz sind die Chefs auch auf die hohe Fertigungstiefe der Spezialmaschinen. Vom einzelnen Zahnrad über die Sensoriksysteme bis hin zur ausgeklügelten Software wird alles komplett in Saal hergestellt. Es gibt ein Konstruktionsbüro, wo neue Produkte entworfen werden, eine Elektrowerkstatt, eine Schweißerei, die Maschinen- und Gehäusefertigung sowie Büros für die Software-Programmierer. Die Mitarbeiter in der Endmontage bauen die Teile zusammen. Vom Auftragseingang bis zur Auslieferung dauert es bei einer Richtmaschine rund zwei Monate. „Zu 90 Prozent gehen sie in den Export, vor allem nach Asien“, sagt Rainer Mestermann. Für den weltweiten Vertrieb hat Mahlo neben dem Stammsitz in Saal Niederlassungen in Italien, Belgien, Spanien, Brasilien, China und in den USA. „Bei unserem Hauptprodukt Richtmaschinen sind wir Weltmarktführer.“
Erfolgsgeschichte beginnt mit dramatischer Flucht
Die Erfolgsgeschichte beginnt 1945 mit einer dramatischen Flucht. Der Physiker Heinz Mahlo verlässt einen Tag vor der verheerenden Bombardierung Dresdens die Stadt und landet schließlich in Saal, erzählt Ralph Greenwood-Mahlo. Dort gründet er im angemieteten Dachgeschoss eines Gasthofs eine elektromechanische Werkstätte und stellt Radiogeräte her. Drei Jahre später gelingt dem Erfinder und begnadeten Techniker der Durchbruch mit dem Feuchtigkeitsmessgerät Textometer. Damit sind die Weichen für die Spezialisierung auf den Textilbereich gestellt. 1959 erfolgt ein weiterer Quantensprung: Heinz Mahlo präsentiert mit dem Orthomat FMC die erste Schussfadenrichtautomatik und erobert damit den Weltmarkt.
Nach dem Tod von Heinz Mahlo 1979 stellt seine Witwe Renate einen Geschäftsführer ein. Das Unternehmen wächst weiter. 1997 steigt Ralph Greeenwood-Mahlo mit 19 Jahren als Gesellschafter in das Unternehmen ein und behält die Strategie mit dem Fremdgeschäftsführer bei.
Mitarbeiter wichtigstes Kapital
Während andere Firmen in Zeiten der Globalisierung mit der Abwanderung in Billiglohnländer liebäugeln, bleibt Mahlo dem Standort treu. „Made in Germany wird von Kunden in anderen Ländern geschätzt“, sagt der Enkel des Firmengründers. „Wir sind ein Familienunternehmen und fühlen uns mit Saal verbunden. Denn unsere Mitarbeiter sind unser Kapital. Manche Beschäftigte arbeiten in zweiter oder dritter Generation im Betrieb.“
Ausbildung hat einen hohen Stellenwert
Einen entsprechend großen Stellenwert legt Mahlo auf die Ausbildung. In der Lehrwerkstatt hängen Zeitungsartikel und Fotos von Azubis, die ihre Abschlussprüfungen mit Bestnoten bestanden. Rainer Mestermann sagt: „Wir bilden gerne aus – zur Mitarbeitergewinnung und zur Mitarbeiterbindung.“ Übrigens fing der heutige Ausbildungsleiter vor elf Jahren selbst als Lehrling bei Mahlo an. Für die Firmenchefs bedeutet die regionale Verwurzelung eine große Stärke des Unternehmens. „Mit den Mitarbeitern aus der Region sichern wir unser Know-how und unsere hohe Qualität.“
Neue Halle für mehrere Millionen Euro
Kunden wie Trigema oder der Edelschneider Zegna wissen das offensichtlich zu schätzen. Die 12 500 Quadratmeter, auf denen Mahlo heute produziert, platzen aus allen Nähten. Gerade entsteht eine neue Halle für mehrere Millionen Euro, um im kommenden Jahr die Fertigung auszuweiten.
“I want to thank you in the name of our company for your commitment, your know-how and your loyalty over such a long period.” These words sent Rainer Mestermann, CEO of Mahlo GmbH + Co. KG to his nine employees who celebrated their anniversary of service in 2017.
It is not a given anymore that you stay with one employer for such long time. But especially the long-term employees, who know the company inside out, are extremely important for the success of a company. 165 years of expertise have the jubilees from 2017 gathered. “The experience that you bring into your work and pass on to your younger colleagues every day is priceless.” A family owned business lives on staff that can identify with their workplace. In recognition of their achievements, the jubilees received a present and a bonus from the management as well as a bouquet of flowers from the works council.
The honourees are from several different departments of the machine builder. From technical engineering over purchasing to production. Staff members with more than a ten year period of employment are honoured. Four times longer than that Frank Ziegler works at Mahlo. Mestermann wished him as well as the others all the best for the future: “Stay healthy and keep having a good time with your job.”
Festivity is a long-standing tradition with machine builder
Out there, through the woods he comes…, and that already for 47 years. That is how long the St. Nicholas celebration is a tradition at Saal-bases machine builder Mahlo. This year, 17 children of employees were pleased with gifts and treats.
In 1970 St. Nicholas parked his decorated sleigh for the first time in the family company’s cafeteria. Then as now, it was packed with surprises. A bright red bobsled, a cozy scarf and of course sweets were waiting for the little ones this time. To shorten the wait until the arrival of Nicholas, a tasty meal and crafting was on the schedule.
The party was first introduced by company founder Dr. Ing. Heinz Mahlo and his wife Renate, as grandson and owner Ralph Greenwood-Mahlo explains: “It was a special cause for both of them to do something for their employees’ children.” As a young boy, Greenwood-Mahlo participated in the festivities, later he joint in with his own son, then as a guest, never missing a year. “The kids’ shining eyes and the excitement just before St. Nicholas arrives is always special, no matter how old you are.” Many Mahlo-employees whose family members have worked here for a long time might feel the same. They had also stood nervously in front of the holy bishop and recited a song or poem for him. Today, it’s the next generation. “To keep this tradition and strengthen the sense of belonging is a great need for the family”, as Greenwood-Mahlo says.
Casting the part of St. Nicholas is also characterized by permanence. For over four decades, former member of staff Georg Neumayer put on mitre, coat and the long white beard. In 2016 he handed over the crosier to Johann Forstner for reasons of age. Forstner takes his duty as serious as his processor. Every single child got his attention and a few nice words. And the promise that St. Nicholas will be back next year.
Full order books, a positive business development: The Mahlo GmbH + Co. KG is currently experiencing tailwinds. At the machine manufacturer in Saal, the demand for its measuring, control and automation systems for the textile and finishing industry as well as the coating, film and paper sector is so high that the spatial capacities are no longer sufficient. That’s why the first cut of the spade for a new assembly hall has been made.
“The new building will host the assembly for our quality control system Qualiscan QMS”, CEO Rainer Mestermann explains. The measuring system collects and controls for example basis weight, moisture or thickness of films, paper or nonwovens. Especially this sector has been growing fast in the last couple of years. More than 100 QMS-machines left the production site in Saal in 2016 – with increasing tendency. “But we don’t have enough production and storage space for these amounts”, says Mestermann. By now, they have already reached their limit. This is why the QMS-assembly is going to move into its new home, which will host modern work spaces for 12 to 15 employees, by summer 2018. Totalling construction, technical equipment and an expansion of parking spaces, Mahlo invests a single-digit million sum.
With 650 square metres, the new hall offers thrice the space than the current solution. You need the size to make effective work possible, Oliver Kastl, head of production at Mahlo, describes the situation. “In the future, we can put a flow production into practice, like we are already doing with our straightening machines.” With this system, the machine is not assembled completely in one spot but passes various workstations one-by-one. That improves the flow of material and reduces the lead time. In addition to that, at Mahlo not only the number of orders grows but also the machines themselves. “At the moment, our biggest machine type is 9 metres long; in the future, we will build units with up to 15 metres. This size is requested more and more frequently by our customers.” Furthermore, the hall provides room for meetings and customer inspections.
Ideal work surroundings for staff and environment
While planning the building, a pleasant working environment has been strongly taken into consideration. “That includes an acoustic ceiling for noise protection and many natural light sources”, says Kastl. And also environmental measures play an important role. An industrial underfloor heating ensures a constant indoor climate without wasting energy unnecessarily. A photovoltaic system on the roof for personal use will cover about half of the company’s power consumption.
The extension is not only a means to create a more effective work environment, as shareholder Ralph Greenwood-Mahlo says: “It’s a clear commitment to the Saal location.” Because the family-owned company will continue to produce exclusively at the main site and count on the worldwide accepted quality “made in Germany”.