A POWERFUL start - Pfisterer

COMPANY MAGAZIN FOR THE PFISTERER COMPANYS IN SWITZERLAND AND SOUTH AFRICA, INCLUDING THE CENTER OF COMPETENCE «OVERHEAD LINES» 01 / JUNI 2006 

Business 

A look back at the 

2005 financial year 

Page 3 

Business 

Connex-Stecker 6 S 

for Grimsel power 

Page 4 

Business 

420kV-solution in 

the desert of Dubai 

Page 6 

Technology 

PFISTERER Pty: New 

DESMA machine 

Page 8 

Group 

PFISTERER Group 

Meeting 2006 

Page 10 

People 

Samuel Ansorge: 

The first 100 days 

Page 11 

On the move 

A new look for PFISTERER SEFAG 

A POWERFUL start 

Hans Wicki 

Managing Director 

Dear Customers, dear Employees 

Spring is here! Once the vegetable and flower 

beds have been dug over and sown with seeds 

and seedlings, there may be a temptation to 

relax and watch the plants come up. This would 

result in a rude awakening however and every 

amateur gardener would refrain from sitting 

back and doing nothing. Because on the way to 

becoming crispy lettuce or sun-ripened tomatoes, 

the young plants have a number of hurdles 

to overcome, such as hungry snails, burgeoning 

weeds and extended periods of dry weather. 

Similar feelings might also be experienced in 

PFISTERER SEFAG now that the reorganisation on 

1.1.2006 has taken effect. Everything was planned 

and organised in such a way that the new 

organisation would be able to get off to the best 

possible start. Careful nurturing is now called 

for. The new procedures have to be put into 

practice and, if necessary, examined critically 

and improved. This will demand great perseverance 

from our employees before the first shoots 

and with them the first successes can be seen. 

Special thanks go to our personnel for the enormous 

effort they are putting in! 

But the harvest is not gathered in yet! «Do not 

let up, but strive constantly for progress, while 

nurturing the team spirit». This is surely also the 

passion that marks out the successful amateur 

gardener. 

In the PFISTERER SEFAG «garden», the Maltersbased 

group division (CoC Overhead Lines) is 

gradually taking shape. Samuel Ansorge, the 

head of this division, and his team are vigorously 

watering and weeding and making strategic 

investments. With the opening of the building 

extension in January 2007, Malters can also look 

forward to the urgently needed seedbed with 

which to increase the harvest. 

The arrival of spring has also been marked in 

our «Connect». The appearance has undergone 

a change and the contents now allow deeper 

insights into the successful operations of the 

PFISTERER Group. We wish you an exciting 

reading – and may your spring sowings bear a 

rich harvest! 

The main entrance in Malters resplendent in the new corporate look. On the right of this building:The new lettering on the roof. 

Since 1.1.2006 we have been operating within the PFISTERER Group’s 

new divisional organisation and under a new business name. Here is a 

brief review and preview of the new organisation. 

Long meetings, lively discussions and 

workshops preceded the launch. All employees 

were kept fully informed during 

this phase and involved in the process. By 

the start of December 2005, the strategy 

board finally agreed the concept and approval 

was given for the go-head. 

The major removal job... 

The go-ahead triggered off numerous activities 

in all areas. Setting priorities was 

the order of the day: what had to be put 

in train by 1.1.2006 to ensure smooth operation; 

which tasks could be undertaken 

during the first quarter of 2006? 

First and foremost was the removal work 

to bring together the teams, some of 

which had only just been formed. The major 

removal work went off smoothly and 

in no time at all, thanks to the tremendous 

commitment of all employees. This work 

was carried out in tandem with the dayto-day 

business, because of course even 

during this period the customer always 

occupied centre stage. 

«New look» 

Another important milestone in the reorganisation 

is the uniform corporate 

identity and the accompanying change 

Continuation page 2

BUSINESS 

1 / 2006 CONNECT 2 

PFISTERER INTERNATIONAL AG 

New sales office in Beijing 

The PFISTERER Group is growing 

for its customers. It has 

recently gained a presence in 

the People’s Republic of China 

by opening its own sales office. 

New look for all employees: the two Managing Directors of PFISTERER SEFAG AG, Hans Wicki (left) and Samuel Ansorge also surprised 

Maria Lustenberger with a T-shirt bearing the new company logo on the first working day of the new year. 

of name from SEFAG to PFISTERER SEFAG 

AG and SEFAG Export AG to PFISTERER IN- 

TERNATIONAL AG. A totally new corporate 

look calls for new letterheads and visiting 

cards, new building and vehicle signwriting, 

as well as changes to the layouts of 

product documents, despatch documentation, 

technical drawings, advertisements 

and brochures etc. – a list as long 

as your arm! 

Thanks to good coordination and the tireless 

efforts of all involved, we also mastered 

this hurdle without encountering 

major problems. On 1.1.2006, the new 

letterheads were ready and telephone 

callers and visitors to the site were welcomed 

with greetings and signposting 

incorporating the new company names. 

Now you will even find us in the dark: the 

illuminated PFISTERER sign on the roof of 

the high-bay racking store now shines out 

in the red corporate colour over the roofs 

of Malters. 

Optimisation and fine-tuning 

Following a hectic period during which 

experience was accumulated and optimisations 

undertaken, a degree of tranquillity 

has been restored. In the meantime, 

customers, partners and employees have 

become accustomed to the «PFISTERER 

SEFAG» name and are beginning to identify 

with it. And now we are setting about 

the fine tuning, to ensure the «new look» 

will also stand up on the catwalk, i.e. in 

the relationship with our customers: to 

build on the strengths in our flexible customer 

service, to draw up and implement 

concepts based on the Corporate Identity 

(CI), to establish and maintain a new corporate 

culture etc. 

Benefiting from common strengths 

What conclusions can we draw from this 

reorganisation? Changes essentially offer 

an opportunity to improve the existing 

situation – at the outset they are 

neither good nor bad. The decisive factor 

is always what we make out of situation 

of this type. With this reorientation, the 

PFISTERER Group has brought all its 

strengths under a single banner. We are 

convinced that with the common corporate 

identity we will attain a stronger 

identification with our customers and 

make their work much simpler. 

PFISTERER SEFAG as the head office of the 

group division (CoC) Overhead Lines has 

been given the opportunity to present itself 

and its familiar brands as a member 

of an internationally integrated group of 

companies. «PFISTERER – the power connection», 

the group with a strong network 

for the benefit of its customers. 

Vreni Schmed 

The first PFISTERER agency on Chinese 

soil opened its doors in the capital Beijing; 

to be more precise in the German 

Centre of the Chaoyang District, where 

many foreign companies and embassies 

have settled. Up to now, PFISTERER 

has enjoyed success in China principally 

through its HV cable products – thanks 

to Jürgen Ziebarth and the staff of the 

PFISTERER agency in Hong Kong. With 

the agency in Beijing, PFISTERER aims to 

continue working in close collaboration 

with Hong Kong to exploit the huge potential 

of this enormous country for the 

entire holding company and all product 

areas. The opportunities are good. 

We are pinning our hopes on China’s 

huge annual growth rate and rapid development. 

In 2004, its electricity consumption 

grew five times as fast as that 

of Switzerland, or put another way, China 

builds the equivalent of the entire Swiss 

infrastructure every ten weeks. This 

rapid pace of development is particularly 

apparent in the major cities, yet it is hard 

to imagine the overall scale. This also lies 

in the size of the rising country, that to a 

European has the size of an entire continent, 

offering everything from an arctic 

climate to a subtropical one. A wide spectrum 

of challenges for which PFISTERER, 

with its equally wide product spectrum, 

is thoroughly well prepared! 

Manfred Peter 

Jan-Henrik W. Kuhlefelt, in 

charge of the new PFISTERER 

agency in Beijing.

3 1 / 2006 CONNECT BUSINESS 

A review of the 2005 financial year in the SEFAG Group 

Constant progress 

The SEFAG Group can again look back on an outstanding operating 

year. After exceeding the psychologically important 100 million mark 

in sales in the previous year, strong progress was made in all key operating 

figures in 2005. 

2005 fully met our expectations both in 

terms of total turnover as well as cash 

flow. We owe this success on the one 

hand to the ongoing strong investment 

and replacement need in the energy supply 

industries in our two domestic markets 

(Switzerland and South Africa), and, 

on the other hand, our continuing efforts 

OPERATING FIGURES FOR THE SEFAG 

GROUP (in 1000 CHF) 

CHF 1’000 2004 2005 

Total sales 111’864 112‘733 

Investment 2’808 2‘602 

Cash flow 5’020 7‘084 

No. of employees 570 658 

to achieve cost leadership. The increased 

competitivity thus obtained is reflecte in 

the improved cash flow and in the current 

very good situation concerning orders. 

The Hardware Assemblies Group acquired 

two years ago represents an important 

pillar of out group. In the meanwhile, it 

has integrated itself into our ranges in the 

best possible way and the high management 

expenditure is more than justified. 

In 2005, SEFAG continued to invest at the 

customary levels in new plant and processes, 

work safety measures and environmental 

protection. The total volume of investments 

across all companies amounted 

to CHF 2.6 million. 

Operating results, as is well known, are 

only a representation of human labour. 

The extension to the CoC Overhead Lines alongside the high-bay 

racking store in Malters is definitely on for 2007. At the moment, 

the provisional building outline frames for the building application 

are in place. 

Despite the changes and amendments 

needed to implement the new group organisation, 

we have together succeeded in 

maintaining our focus on our most important 

goals, that is to say customer and employee 

satisfaction. We have every reason 

to be optimistic that our «good gut feeling 

for 2006» will not prove deceptive. 

Hans Wicki 

Speedcraft Manufacturing (Pty) Ltd 

Local success in South Africa 

Speedcraft Manufacturing (Pty) 

Ltd is a manufacturer of metal 

hardware, all of which has applications 

in the electrical transmission 

and distribution industry. 

Through its association with 

Hardware Assemblies, Speedcraft 

is now a member of the PFISTE- 

RER Group of companies. 

The partnership between these companies 

was borne out of Eskom’s mandate 

to empower black business and their 

encouragement for the two to formally 

join forces. Speedcraft has positioned its 

own production facilities next door to the 

PFISTERER premises in Pietermaritzburg, 

thereby enabling the company to make 

use of our infrastructure. The company 

enjoys access to a wealth of expertise and 

support from within the PFISTERER Group 

and is ideally positioned to continue growing 

from strength to strength as a leading 

supplier and as a contributor to the ideals 

of black empowerment in South Africa. 

Empowerment of the disadvantaged is at 

the forefront of South African commerce 

and industry. Eskom, as a parastatal corporation, 

is particularly vigorous in its 

pursuit of these ideals and places a high 

premium on black and particularly black 

woman ownership (BWO) of businesses 

that they deal with. Because of the obvious 

benefits such as job creation in large 

numbers, they also prefer to deal with 

empowered companies that are also bona 

fide manufacturing operations. Speedcraft 

is one such manufacturing concern 

which together with its new management 

structure, ensures a very high rating 

on the supplier ranking system used by 

Eskom. 

In line with the commitment by the South 

African government and the endorsement 

by PFISTERER of the principles and values 

Speedcraft Manufacturing production facilities in Pietermaritzburg 

and their Managing Director Orene Mnguni. 

of black economic empowerment in South 

Africa, Speedcraft is quickly transforming 

itself into a company where women are in 

the majority. In keeping with this BWO-vision, 

Ms. Orene Mnguni in her position as 

Managing Director is working hard to accelerate 

the process. 

Staffing of the company has grown tenfold 

since 1999 (when Hardware acquired 

the 50% stake which now belongs to 

PFISTERER HOLDING AG). Speedcraft has 

earned ISO 9001 2000 certification from 

the German accreditation company DQS 

and is looking forward to exciting and 

profitable times in the near future, watch 

this space! 

Rob Schorn

BUSINESS 

1 / 2006 CONNECT 4 

Local Sales Organisation Switzerland (LSO): Connex connector system size 6 S for 245 kV 

Connex in use for power from the Grimsel region 

Kraftwerke Oberhasli AG operates a network of nine hydraulic power 

stations in the Bernese Alps with a total output exceeding 1000 

MW. The goal of its ongoing multi-million investment program «KWO 

Plus» is the refurbishment and upgrading of plant. In the process, the 

operating company is putting its trust in PFISTERER SEFAG connection 

technology. 

Up to now, the energy has been supplied 

to the partner at a single node on the grid 

in Innertkirchen. A need for major refurbishment 

now exists in the plants which 

came into service between 1932 and 1980 

as well as opportunities to improve the 

complete system by selective upgrading 

in certain areas. In the Aare Valley, the 

stations are situated at the following altitudes: 

Grimsel region approx. 1760 metres, 

Handeck region approx. 1300 metres, 

Innertkirchen approx. 620 metres. 

Beautiful view over the Grimsel region in the Bernese Alps. 

With the exception of the Grimsel region, 

the KWO’s entire energy output is brought 

to Innertkirchen at the 150 kV voltage 

level. Only one 150 kV line leads from Innertkirchen 

however, all other lines are 

operated at a nominal voltage of 220 kV. 

This means that most of the energy has 

to be inefficiently transformed in Innertkirchen. 

Replacement requirement in the 

Handeck 

The plants on the Grimsel with their 220 kV 

supply are still in prime condition. In recent 

years, almost unnoticed, the transformers 

in the Innertkirchen control centre 1 have 

been replaced by new ones with plugs in 

size 6 (150 kV) in the lid (the optimum solution 

in respect of the routing for the feeder 

cable). The plants of the three power stations 

on the Handeck, currently operated at 

150 kV, were showing signs of ageing, however. 

Despite the relatively young age of up 

to 55 years, these parts had to be replaced. 

Identical replacements were out of the 

question because among other things, the 

Handeck 2 control centre was connected to 

the grid via two three-phase 150 kV cable 

looms, 6 km long, through the Handeck 

– Guttannen railway tunnel. Replacement 

of this cable would have been ridiculously 

expensive in relation to the benefits, especially 

in view of the price of the potential 

solutions available today. The two other 

control centres were supplied via a line designed 

for 220 kV but operated at 150 kV. As 

part of a possible expansion of the plants 

on the Grimsel (next higher level), it should 

be possible to utilise this line with 220 kV 

for the control centres on the Grimsel. Renewal 

of the lines had to be avoided. 

Connex, the power connection, also for 245 kV. 

Change of voltage 

In order to achieve efficient energy transmission, 

the Handeck region is now to 

be linked at the 220 kV voltage level. 

New 220 kV switchgear was envisaged 

in the Handeck region for this purpose. 

The change of voltage also involved replacement 

of all transformers and their 

feeder cables. Since the feeder cables between 

substations and transformers were 

largely to be laid along the course of the 

old routes, a change of this type required 

time. Consequently, the work is to be carried 

out in three stages – autumn 2005, 

spring 2006 and autumn 2006. 

Since the Innertkirchen – Grimselpass – 

Nufenenpass – Ticino power stations 220 

kV line crosses the KWO power station almost 

exactly over the new 220 kV switch- 

Transformer connection.


gear, adding this line to the loop was an 

obvious thing to do. This line is owned by 

the same partners as own KWO. It was 

therefore possible to add the two branches 

into the loop of the new Handeck 

switchgear. Following the commissioning 

of the new switchgear, it was then possible 

to connect one control centre after the 

other with new transformers to the new 

switchgear. Since the transformers and 

their feeder cables were to be erected by 

and large in the same location as the old 

plant, they had to be replaced on a step by 

step basis. 

PFISTERER connection technology offers 

decisive benefits 

Soon the question of termination technology 

arose. For the transformers, it 

was quickly resolved: the binding order 

envisaged PFISTERER size 6 S plugs. In the 

Handeck case, not only was it necessary 

to provide for a reserve field, the planned 

fields had to be connected within one year. 

With the existing connection technology 

a gas-filled compartment would have 

to be opened each time for this purpose 

and the affected parts of the switchgear 

retested afterwards. The tests take up a 

great deal of time and the ensuing costs 

are very high. 

When using plugs on the other hand, the 

switchgear can be tested on completion 

(the plug sockets are fitted with dummy 

plugs during the testing). This unique 

advantage offered by plugs resulted in a 

triumph for this technology over the «it’s 

always been done this way» approach 

and the way was open to employ the new 

plug technology on the switchgear (with 

its dreaded overvoltages). The second triumph 

for the technology was that the test 

results held sway over reference lists. 

Erection and fitting 

The next step was to fit the plugs, a task 

that may only be undertaken by certified 

personnel. Even though just a few 

grams of grease instead of several litres of 

oil were used for the fitting, it went like 

clockwork. The result was a major saving 

in time, together with lower fitting costs. 

Due to the good experiences, the same 

Switchgear with Connex size 6 S. 

fitters want to come again for the fitting 

of the plugs to the cables on the other 

transformers. 

Checking the plant 

On conclusion, the new components had 

to be tested. Here it became apparent 

that it was not possible to carry out a test 

in the way demanded without a plug. It 

was necessary to test the cables with the 

fitted terminations. However, the mobile 

test unit was unable to test the transformer 

as well at the same time. 

For this reason, the transformer was supplied 

with power and tested at the plug by 

means of a mobile partial discharge measurement 

unit and with fixed partial discharge 

probes on the side of the switchgear. 

First the cables were tested with the 

fitted plugs, then a little later the switchgear 

was tested again on account of an 

opening of the gas-filled compartment in 

the meantime. The cable suppliers were 

required to confirm that the cables were 

able to withstand this long test. No-one 

asked the plugs! 

As confirmed by the customer, the following 

advantages of plugs were demonstrated: 

1. The only termination technology that 

allows fields (e.g. reserve fields) to be 

connected at a later date on gas-filled 

Technical data 

The Siemens gas-insulated switchgear, 

type 8DN9 has 4 feeds, 6 transformer 

fields, 1 cross coupling and 1 busbar longitudinal 

separation. 

Nominal data: 

Rated voltage: 245 kV 

Rated current, busbar and feeders: 3150 A 

Rated current, transformer branches: 2200 A 

Rated short-term withstand current: 40 kA 

The transformers made by EBG Trafo 

have 70 MVA and are designed without 

step switch. 

Connection to the switchgear is realised 

with a 300mm 2 high voltage cable. 

The transformers are notable for their 

water cooling systems. This technology 

lends itself particularly for use here, because 

the circulating water has a temperature 

of only around 10° C. 

systems – without having to open the 

gas-filled compartments, involving 

subsequent retesting. 

2. Fast and neat assembly that will stand 

up to subsequent testing 

3. Flexibility in terms of testing. 

Walter Bachmann

BUSINESS 

1 / 2006 CONNECT 6 

CoC Overhead Lines: compact power line for the Dubai Electricity and Water Authority (DEWA) 

A powerfull 420 kV-solution for Dubais 

electricity supply 

Dubai provides not only the fabric from which the tales of the 1001 

Nights are woven: sun, desert, beach. The second-largest of the seven 

sheikhdoms making up the United Arab Emirates (UAE) has for many 

years been investing huge sums to secure its economic future. And to 

do this it needs a great deal of electrical energy. PFISTERER SEFAG is working 

there with a sophisticated special solution for the development of 

the electricity network in the desert. 

Dubai is regarded as a popular Arabian metropolis 

for shopping tours. Almost 100% 

probability of sun and a sophisticated infrastructure, 

such as an artificial ski slope 

for skiing, with the Burj al Arab the world’s 

only seven star hotel, large, modern building 

complexes as well as man-made islands 

with exposed beach position (picture 

1) come together on 3900 km 2 . 85% 

of the Emirates population – estimated at 

1.4 million in 2005 – consists of foreigners, 

a figure that is continuing to grow. 

The high infrastructure investment is leading 

to a disproportional demand for electrical 

energy in comparison with Europe. 

Part of the reason for this is the installation 

of air-conditioning as a standard feature. 

To supply the electrical energy from 

distant power stations and to achieve the 

necessary grid interconnectivity to ensure 

optimum security of supply, new lines of 

up to 420kV are called for. 

Challenging project in the desert 

Whereas transmission line routing 

through desert regions is not particularly 

critical in terms of planning restrictions, 

access problems in built-up areas can demand 

custom solutions. This will become 

clear with the situation in pictures 2a and 

2b. These reflect the critical construction 

phase of the new 420kV line from Mushrif 

to the Nahda substation. An additional 

transmission line is envisaged on the 

right-hand side of an existing 420kV line 

(picture 2a). A comparable conventional 

construction is not possible due to the 

parallel road and border with the neighbouring 

Emirate of Sharjah. The solution 

consists in the erection of a compact line 

in this part of the route (picture 2b). Although 

having the same transmission capacity 

and voltage level, the compact tower 

appears almost delicate in comparison 

with the conventional solution. PFISTERER 

SEFAG was the sole remaining supplier for 

an isolated crossarm for this line section. 

Third generation of compact power lines 

The following challenges had to be taken 

into account in the design: 

1: The Palm Islands, 

also referred to as 

The Palm Dubai 

and The Palms, are 

the three largest 

man-made islands 

in the world, which 

are being built on 

the coast of the 

emirate of Dubai, 

in the United Arab 

Emirates (UAE). 

2a: Existing 420 kV Line. 

2b: Planned Compact Line (right).


PFISTERER IXSOSIL AG 

Even more power for Altdorf 

It is already four months since 

the go-ahead was given for the 

new «Cable Systems» Centre 

of Competence containing the 

two production sites at Altdorf 

and Winterbach. 

3a: Initial Design with double Post. 3b: Optimized Design with single Post. 

– Insulation coordination (BIL, SIL) 

– high creepage path requirement with 

55 mm/kV 

– lowest possible protrusion in order to 

maintain the phase safety distance within 

the new line and to the adjacent system 

– Stringent mechanical requirements, 

greatly characterised by wind load on 

the four-conductor bundle and disproportionately 

high force distribution 

during maintenance work 

– Short-circuit current of the power protection 

fittings 63kA/1 s 

– Wind-induced swing angle of the suspension 

clamps. 

These rather complex, to some extent 

interdependent specific issues for this 

project led to a solution that might 

be described as the 3rd generation of 

PFISTERER SEFAG compact power line systems 

for 420 kV. Whilst the EOS «pioneer 

line» in 1998 was still executed with a hollow 

post insulator, today solid core post 

insulators are used as a matter of preference. 

The development of this project 

becomes clear through a comparison of 

the assembly drawing at the start of the 

project and after the optimisation phase 

(pictures 3a and 3b). 

The original solution (3a) envisaged two 

parallel post insulators. As well as being 

more expensive, two fundamental disadvantages 

may be encountered: 

– Minor differences between the two 

posts occurring as part of the production 

process may lead to asymmetrical 

loading and an (elastic) buckling below 

the design specification. 

– In the event of dirt accumulation, parallel 

discharges between the two posts 

might seriously reduce the breakdown 

voltage compared to a single insulator. 

The solution approved by the customer 

(picture 3b) consists of a single post insulator. 

The high creepage distance was realised 

with special underrib sheds.. 

It was possible to determine the optimum 

dimensions precisely by means of FEM 

simulations (picture 4a) and full-size practical 

trials on a test rig (picture 4b). 

The definitive order was placed at the start 

of April, the mechanical and electrical acceptance 

testing is scheduled for June. We 

would like to thank the personnel involved 

for their intensive work on this time-sensitive 

and technically challenging project. 

Walter Fluri, Wolfgang Huiber, Dr. Frank Schmuck 

It is satisfying to see that the immense 

preliminary planning work has by now 

largely been implemented and is already 

beginning to bear fruit. 

Transfer moulding capacity doubled 

As an initial milestone within the new 

Centre of Competence, the production 

capacity in Altdorf was recently almost 

doubled in this area by the introduction 

of a second computer-controlled silicone-rubber 

transfer moulding press 

for the manufacture of conductive 

control components used in our highvoltage 

accessories. This increase in 

capacity at all levels of the production, 

logistics and offices virtually coincided 

with a modest increase in personnel 

numbers. This represents a first step 

in order to prepare ourselves for the 

clearly discernible increase in activities 

throughout our sales companies operating 

all over the world. We are convinced 

that the adopted path of amalgamating 

Altdorf and Winterbach is the only 

correct course of action in the present 

era of globalised markets. Together 

with our colleagues in Winterbach, we 

will continue to collaborate on the outstanding 

and initiated projects with 

great dedication and commitment at 

all levels and on an international basis. 

4a: FEM Simulation for Buckling Investigation. 

4b: Real-life Set-up. 

Heinz Schneebeli

BUSINESS / TECHNOLOGY 

1 / 2006 CONNECT 8 

CoC Components 

The Components division continues to evolve... 

The «Components» division came 

into being on 1.1.2004 out of the 

amalgamation of the «Classic» 

and «Distribution» divisions. An 

analysis conducted two years ago 

showed that the «Flexible connectors 

/ OEM products» areas in 

particular had great potential for 

growth. 

In this area, PFISTERER SEFAG mainly manufactures 

products for the plant and engineering 

industry. The most important 

products are: 

• Presswelded flexible copper connectors 

• Braided connectors up to 2500 mm2 

• Bus bars made of copper and aluminium 

• Special connectors for power transmission 

• Top connectors for cable terminations. 

Systematic investment in the production 

area has made it possible to improve processes 

and expand the product area. Among 

these was the equipping of a pressure 

welding machine to enable it to weld areas 

up to 320 mm x 110 mm. An additional installation 

allows us to carry out the brazing 

process more efficiently. With the aid of a 

400-tonne press, we are able to execute 

orders for stamping, pressing and forming 

flexibly and quickly. We accompany many 

projects from the design stage to start of 

production. Here, our know-how and experience 

enables us to offer our customers 

specific and expert advice. 

The strong growth in sales which we have 

been able to achieve in this area is evidence 

that PFISTERER SEFAG is on the right 

course in this area too. 

Jörg Fries 

A few typical products. 

CoC Overhead Lines: New Injection Moulding Technology for PFISTERER (Pty) Ltd. 

CoC Overhead Lines 

PFISTERER (Pty) Ltd. has recently 

purchased a new DESMA injection-moulding 

machine, which is 

part of the long-term strategy of 

upgrading the moulding technology 

in the company. The machine 

will be used in expanding the 

production of insulators and offers 

better repeatability than the 

existing Rhema machines. 

The machine offers a fully controlled 

pressure monitoring injection system together 

with vacuum moulding facilities. 

The Desma logs all pressure and temperature 

variations in a graph format for 

easy diagnostics and optimization of the 

settings on the machine. The controls incorporate 

a mould data saving function, 

which stores the particular settings for 

the various moulds and also stores a history 

of any changes to these settings that 

are made. 

Rob Schorn 

Since the purchase of the machine, it has 

proven itself reliable and consistent, producing 

quality moldings every injection. 

The new Desma machine is a 250-ton 

machine with a shot capacity of 2litres of 

silicone and is capable of moulding a double 

cavity 33kV line post mould. The injection 

pressure from the machine is almost 

three times that of the existing machines, 

ensuring a sound product. 

Original Rhema 160-ton machine. 

The new Desma 250-ton machine.

9 1 / 2006 CONNECT 

TECHNOLOGY 

CoC Components 

SICON shear bolts – what a fit! 

Bolts or compression connectors? The fitting technology industry has 

provided many answers to this question, until a clear trend towards 

terminals, connectors and cable lugs with screw technology established 

itself in recent years. With SICON, the first stepless shear bolt, 

PFISTERER is setting new benchmarks in screw technology. 

When entire networks were being established 

during the building boom between 

1950 and 1990, compression was the inexpensive 

solution for the manufacture of 

many connections with the same crosssection. 

The advance of screw technology 

is the natural response to the current state 

of affairs: different networks exist which 

have to be maintained or expanded. 

Here screw connectors offer technical 

and practical benefits which compression 

connectors are unable to match. Screw 

technology enables a wide spectrum of 

possible cross-sections to be dealt with 

easily, with the result that this clamping 

technology perfectly suits the new multirange 

cable accessories. Fitting is carried 

out with simple tools in next to no time. 

The current level of screw technology is 

based on the «multi-stage shear bolt». The 

design strength of multi-stage shear bolts 

– the integral predetermined breaking 

point – is also their crucial weakness. Each 

rupture point interrupts the load-bearing 

thread, therefore the maximum clamping 

force cannot be utilised. 

New from PFISTERER: stepless shear bolts 

Improving this tried and tested technology 

proved to be a challenge for PFISTER- 

ER. SICON, the first stepless shear bolt, is 

our response to it. Its special design feature: 

no predetermined breaking points 

in the thread. In this way we achieve an 

optimum thread load bearing capacity 

for each cross-section range. The use of 

SICON also speeds up the installation procedure. 

The bolt ruptures gently, almost 

without a jolt. That not only simplifies the 

tightening procedure, it also reduces the 

risk of injury. Bolt residues remain on the 

tool and can be safely disposed of. Timeconsuming 

reworking is also eliminated: 

the bolt’s shear point is always on the surface 

of the clamp body – with no projections, 

nothing to be filed off so that the 

joint fits. 

Martin Schuster 

CoC Railway Catenary Systems 

Important actions have been taken 

CoC Railway Catenary Systems is the division of the PFISTERER Group 

responsible for the design, production, marketing and service of all 

the necessary parts for the electrification of railways lines. 

The CoC Railway Catenary Systems has the 

aim to be Cost leading in catenary fittings, 

especially in forging and stamping alloys of 

copper as well as being Technology Leaders 

in catenary compensating devices. 

To achieve these goals, the Railway Catenary 

Systems division will concentrate 

manufacturing to reduce overlaps. 

With this new organization, the CoC will focus 

mainly in the most important markets 

in Europe (Germany, Italy, Spain) and in China 

where the market is growing very fast. 

During the first business period of the CoC 

some important actions have been taken. 

Summarizing: 

– Homologation and first installation of 

Section Insulators in Italy. Besides, it is 

very near the qualification as producers 

of CuNiSi fittings for railways. 

– Homologation and first sales of the 

Laser Telemeter in Germany as well as 

the homologation of the hangers. Some 

other fittings are now in process to be 

homologated as well. 

– Some deliveries of fittings for the maintenance 

of railway lines in China. 

– Contract for the supply of hangers, 

clamps and fittings for the electrification 

of a new line of 600km in China 

(Tianjin-Shenyang) 

– Contract for the supply of cantilever 

insulators and catenary fittings for the 

renovation of a line in Turkey (Istanbul– 

Ankara). 

– Important deliveries of catenary fittings 

for the High Speed lines in Spain. 

– First installation and delivery of section 

insulators in South Africa. 

Jacinto Roca 

First installation of a Section insulator 

in Italy (Formio Station) 

Development of the new Laser 

Telemeter and adaptation into the 

international markets requirements 

Production of fittings for High 

Speed Lines

GROUP 

1 / 2006 CONNECT 10 

PFISTERER Group Meeting 

High-powered Group presence 

In January, representatives of all PFISTERER subsidiaries met up again 

for the third time at Winterbach to attend an international meeting. 

And it was a high-powered presence. 

Acquisition of the co-partner’s 

share in UPRESA S.A. Barcelona/ 

Spain 

On 7 April UPRESA S.A. became a fully 

owned subsidiary of PFISTERER HOLDING 

AG. UPRESA was founded in 1972 and until 

recently had two other co-partners. The 

company is not only the base of the CoC 

Catenary Systems, it is also a successful 

national company in the Spanish and Portuguese 

market. PFISTERER HOLDING has 

now acquired the shares owned by Finelectric 

Anstalt and Arthur Flury AG. 

The participants at the PFISTERER group meeting assemble for the obligatory group picture in front of the group headquarters in 

Winterbach. 

From left to right. Juan Hernandez-Canut (Finelectric Anstalt), 

Dr. Jost Baumgärtner (CFO PFISTERER Holding AG), Jacinto 

Roca (Managing Director UPRESA), Dr. Konstantin O. Papailiou 

(CEO PFISTERER Holding AG) and Adrian Flury (Arthur Flury AG) 

on the occasion of the signature of the purchase contracts in 

Winterbach. 

Frank Schmuck (right) explains the latest technological developments 

from CoC Overhead Lines. 

Entirely in line with the motto «PFISTERER 

– The Power Connection» a total of 65 

participants from 14 countries attended to 

find out all about the CoC’s new product 

innovations, new market potentials and 

the group’s strategic objectives, as well as 

to meet up with new and old colleagues 

for an intensive exchange of ideas. 

Attending for the first time were representatives 

from PFISTERER U.K. founded 

at the start of the year in Oakham (Great 

Britain), as well as delegates from the 

PFISTERER agencies in Hong Kong and 

Beijing (People’s Republic of China). One 

of the highlights was the product show 

in the form of an in-house exhibition, in 

which each of the four Centres of Competence 

graphically demonstrated its new 

Jörg Fries (right) presents innovations from the components 

area. 

products and further developments, supported 

by detailed explanations by the 

product manager concerned. 

Susanne Müller 

Shop talk and discussions among power colleagues. 

Prominent anniversaries 

Who says that a managerial existence only 

has to be oriented towards short-term 

personal gain? Our two most prominent 

PFISTERER members celebrating their anniversaries 

in 2006 are living evidence to 

the contrary. 

Dr. Roland Walthert, Chairman of the Supervisory 

Board of the PFISTERER HOLDING 

AG and President of the board of directors 

of the Swiss companies, for 15 years in his 

highly responsible role. 

Dr. Konstantin O. Papailiou, Chairman 

of the Board of Directors of PFISTERER 

HOLDING AG is even able to look back on 

20 completed years of service in several 

functions within the PFISTERER Group. On 

3 July, Konstantin O. Papailiou will also be 

celebrating a milestone birthday. 

Congratulations and best wishes on behalf 

of everyone in the company!

11 1 / 2006 CONNECT PEOPLE 

Samuel Ansorge, Head of the CoC Overhead Lines (OHL) 

The first 100 days in office 

Samuel Ansorge, for the last 100 days 

Malters has been your new place of work. 

What has personally changed for you? 

A lot of exciting and new things came at 

the beginning of the year: new place of 

work, new environment, co-operation 

with a new team. After having previously 

led SEFAG Ixosil AG as a rather straightforward 

enterprise with some 40 employees, 

the function of CoC manager represents 

an entirely new responsibility. Now I am 

concerned with a very competitive business 

field with two locations in different 

continents, Malters (CH) and Pietermaritzburg 

(SA). This means two different cultures, 

which must be strategically «synchronised». 

Another exciting aspect was 

also for me to get to know new, although 

related products. 

The first 100 days in office interview: neither politicians 

nor OHL leaders are spared. We at Connect 

wanted to know, how the Ixosil business manager 

of many years, ETH electrical engineer and sporty 

«Marathon man», Samuel Ansorge, experienced his 

first 100 days in Malters. 

How is the start of the new PFISTERER 

Overhead Lines Division going? 

So far we are satisfied with the start in 

2006. The key problem today is the rising 

raw material prices which we have to pass 

on to the customers after a certain delay. 

In addition, at the moment we have a very 

limited manufacturing capacity which 

leads to unacceptably long delivery times. 

But the Board of Directors has already 

given the green light for the expansion 

of manufacturing this year which is very 

positive and an additional motivation for 

the whole OHL-team. This expansion covers 

a new building and investments in 

machines. Both are very important milestones 

for Malters and also for our future 

success. 

What has particularly impressed you in 

your start-up phase? 

Externally: the excellent sales network 

with good customer contacts, our very 

good name in the market and our very reliable 

products. Internally: the high technical 

competence and the willingness of the 

employees. 

What tasks are next on the agenda? 

In the short term, the realisation of the 

new building and the expansion/development 

of the insulator manufacturing. In 

the medium term, we want above-average 

growth in the areas of long rod and 

hollow insulators. 

In addition, in the context of the establishment 

of the new CoC structure, the fine 

tuning of the processes remains an on-going 

task over the coming months. 

We would like to take this opportunity to 

thank you for this interview and wish you 

all the best for the future. 

New Editor in Chief 

This edition of «Connect» marks 

not only a change in style but 

also a change in the coordination 

of our company magazine. 

Gudrun Brunner has edited «Connect» for 

a total of 10 issues. In that time, she always 

succeeded in drumming up enough 

articles in time for the copy deadline 

which often bordered on a miracle in 

view of her other demanding role as director’s 

assistant and the authors’ many 

absences on customer visits. With patience, 

persistence and a keen sense of 

what constitutes a readable blend of 

company and employee-related topics, 

Gudrun Brunner made a highly positive 

contribution to the 2001-2005 issues of 

our company magazine. We would like to 

take this opportunity to express our sincere 

appreciation. 

Overall coordination of «Connect» now 

lies with Vreni Schmed, Corporate Marketing 

of PFISTERER SEFAG AG. The proud 

mother of two children aged 12 and 15, 

joined the company in October 2000 as 

a secretary in the Classics area. Following 

her successful training as a marketing 

assistant and marketing communication 

planner at the Institute for Further Education 

(IWB) in Lucerne, she was able to 

take on the newly created function of 

«Corporate Marketing» for the PFISTERER 

companies in Switzerland on 1.1.2006. Uppermost 

among Vreni Schmed’s tasks at 

Gudrun Brunner hands over her role to the new Connect coordinator 

Vreni Schmed(right). 

the present moment is the implementation 

of the PFISTERER Group’s new corporate 

design (see Connect 2/05). This has 

already been completed for the company 

magazine. The website, brochures and 

other printed matter will follow gradually. 

Vreni Schmed looks forward to receiving 

what she hopes will be many suggestions 

for articles from you! 

Brigitte Senn

PEOPLE 

1 / 2006 CONNECT 12 

New employees 

Happy Birthday 

PFISTERER SEFAG AG 

PFISTERER IXOSIL AG 

50 th birthday 

Monika Hänsli 

PFISTERER IXOSIL AG (23.02.) 

40 th birthday 

Robert Feusi 

PFISTERER SEFAG AG (02.03.) 

Silvia Bäck 

Design Engineer 

Product Management 

Components 

Date of joining 01.01.2006 

Petra Arnold 

Assistant 

Product Management 

Systems 


Marian Gubis 

Design Engineer 

Development & Technology 


Armagan Elbir 

Employee 

Logistics 


Martin Hauser 


Stephan Meier 


Success 

Sonja Gäble 

Assistant 

Product management OHL 


Firat Karlidaq 

Employee 

Production 


Hans Schweizer 

Fitter 

Installation 


At the local elections of 21st May, Hans Wicki, Managing 

Director of PFISTERER SEFAG AG, was elected as President of 

the municipality of Hergiswil/NW. The FDP (Free Democratic 

Party) politician has belonged to the local council of the 

approximately 5500 inhabitants on the Vierwaldstättersee 

(Lake of the Four Forest Cantons) for six years. At present, he 

heads the section responsible for public works (water, rivers 

etc.). PFISTERER SEFAG AG is proud to now have the president 

of a municipality in their ranks. We warmly congratulate Hans 

Wicki on his election and wish him further success in both 

politics and business. 

Service anniversaries 

Transfers 

Agenda 

40 years 

Robert Unternährer 


35 years 

Walter Bachmann 


Manfred Peter 

PFISTERER INTERNATIONAL 

AG (01.04.) 

25 years 

20 years 

Dr. Konstantin O. Papailiou 

PFISTERER HOLDING AG 

(01.01.) 

15 years 

Franz Bienz 


Marco Novi 


Dr. Roland Walthert 

PFISTERER HOLDING AG 

(01.01.) 

10 years 

Maria Lustenberger 


Samuel Ansorge 

Head of CoC OHL 

From SEFAG Ixosil AG to 


Thomas Bachmann 

Product Management OHL 

From SEFAG Export AG to 


Claire Duss 

Bookkeeping 



Bruno Egli 




Robert Feusi 




Martin Hauser 




Wolfgang Huiber 




Roger Kempf 

Logistics 



Christine Kunz 




Sergio Mattiello 




Garth Smith 

Sales Area Manager Afrcia 

From PFISTERER (Pty) Ltd. to 

PFISTERER INTERNATIONAL AG 

Erwin Steinmann 

Bookkeeping 


PFISTERER IXOSIL 

June 2006 

2. Staff-meeting, 

Malters 

16. Inter-company football 

competion Malters 

(Premiere of the new 

PFISTERER SEFAGdresses!) 

December 2006 

1. Staff-meeting, 

Malters 

15. Christmas Party 

PUBLISHER’S DETAILS 

Connect 

Company magazine of the 

PFISTERER companies in Switzerland 

and South Africa and the 

group division (CoC) Overhead 

Lines 

14th year of publication – No. 1/06 

– published twice a year 

Circulation: 1500 copies each in 

German and English 

Coordination: Vreni Schmed, 

PFISTERER SEFAG AG, Corporate 

Marketing, Werkstrasse 7 

CH-6102 Malters 

Tel. ++41 41 499 72 51 

Fax ++41 41 497 34 73 

E-mail: vreni_schmed@sefag.ch 

Gerardo Casale 


Paul Hollenwäger 

Logistics 



Sergio Thaddey 

Development & Technology 



Editiorial/layout: www.amk.ch 

Printed by: Engelberger Druck AG 

Last date for copy 2/06: 

30 October 2006

A POWERFUL start - Pfisterer

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