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Issue 1 / 2009 / www.watzhydraulik.de 

Inside Hydraulik 

The Official WATZ Hydraulik Newsletter 

When it comes to efficient 

power transmission, you can rely 

on WATZ Hydraulik

Inside Hydraulik – The Official WATZ Hydraulik Newsletter 

Contents 

Always on the move 

3 Pressure: The most natural 

thing in the world – for WATZ 

4 Where quality saves lives 

5 Successful plant engineers 

rely on WATZ hydraulics 

technology 

6 Perfect porcelain requires 

perfect technology 

7 Precision meets performance 

8 Finding solutions where no 

solutions can be found 

9 Why look far ... 

Big performance, small space! 

10 Moving water in massive 

amounts 

11 Digging for black gold 

12 Rings and wheels for the 

automotive industry 

Imprint 

WATZ Hydraulik GmbH 

Auweg 8 · 35457 Lollar · Germany 

Phone +49 (0)64 06 91 02-0 · www.watzhydraulik.de 

Over the past few years, hydraulics 

engineering has been increasing in 

significance in all areas of drive and 

control technology, in particular, the 

fields of machine, plant and vehicle 

construction. At the same time, client 

demands on quality and efficiency of 

the systems in use have also increased 

greatly. WATZ Hydraulik has been 

meeting the challenges of these markets for over 35 years. 

Moving in sync with the market and the constantly changing 

technical demands, WATZ Hydraulik has never slowed in 

offering its clients innovate and industry-spanning hydraulics 

products. With hydraulics engineering being, as a rule, an integral 

component of an overall system, WATZ constructors 

and technicians have been trained to collaborate with mechanical 

engineers and plant constructors in elaborating plans, 

schedules and everything else needed to carry out a project 

successfully. This is the only way to develop optimum solutions 

while avoiding later alterations and modifications, 

which are always costly and often unnecessary. WATZ Hydraulik 

produces made-to-order constructions and refines 

these as specific large-batch or small-batch production 

models according to customer requirements. The following 

pages will offer you some insight into the diversity of 

WATZ Hydraulik’s range and service spectrum. Countless 

industries around the world stay on the move thanks to 

hydraulics products produced in Central Hesse – from 

materials handling technology and foodstuffs preparation all 

the way to the demolition of chemical weapons. Wherever 

one requires the efficient transmission of power, you’ll find 

WATZ products doing the job. 

And if you turn over this newsletter, you’ll be able to 

become better acquainted with FAUDI GmbH. At home in 

the filtration industry, this long-standing firm entered a business 

partnership with WATZ Hydraulik GmbH in 2006. Both 

companies are experts in the field of special purpose machinery 

manufacture. Using this and many other synergies is the 

secret behind the success of our business collaboration. We 

hope you’ll find this newsletter informative and inspiring. 

Best regards, WATZ Hydraulik GmbH 

Horst Watz 

2 | 3


Examples of Nature 

Pressure: 

The most natural thing 

in the world – for WATZ 

Learning from Mother Nature? That’s nothing new. The 

lessons of nature have, after all, been behind countless lifechanging 

inventions. Today, nature continues to serve as 

a shining example for process efficiency and state-of-theart 

technology. At WATZ Hydraulik, we too are inspired by 

nature when it comes to developing new hydraulics technology. 

And it’s no surprise, really, with nature performing 

massive force transmission, often on the smallest scale, or 

changing momentum at will. Care for an example? Let’s take 

the sperm whale, which uses an ingenious system to reach 

the oceans’ deepest depths. 

A sperm whale’s brain is known to hold some 2,000 kg 

of “spermaceti”. This wax-like substance enables the sperm 

whale to dive to great depths while also helping to control its 

buoyancy. The density of spermaceti changes with the influx 

and efflux of water. It makes it possible for the whale to dive 

with a minimum exertion of energy. With a decrease in temperature, 

spermaceti forms brilliant white crystals. This densification 

leads to an increase in weight, thereby enabling 

the sperm whale to sink more easily. When hunting at great 

depths, sperm whales use up their oxygen, thus generating 

heat and melting the spermaceti. Despite utilising hydrodynamic 

force, i.e., by swimming, the sperm whale is nevertheless 

able to continue its dive. Once it is ready to resurface, 

the sperm whale simply expels the sea water from its body 

and begins to ascend. 

Nature gifted the sperm whale with this natural technology. 

If it hadn’t, WATZ would surely have helped the sperm 

whale on its way. Aside from the development and production 

of customised hydraulic systems, WATZ also sets itself apart 

from its competitors by offering comprehensive customer 

service. At WATZ, we support our customers as early as the 

planning stage, ensuring that clients receive individual care 

and attention, customised to suit their individual demands. 

Work processes are coordinated automatically, thereby guaranteeing 

absolute precision in handling and application. And 

that saves both time and money!


Technology developed by WATZ Hydraulik in action against chemical weapons 

Where quality saves lives 

Chemical warfare ranks as the most dangerous, the most 

deadly and the most feared method of waging war. At the end 

of World War II, the use of chemical and biological weapons 

was prohibited by the international community. Since then, 

aside from the numerous violations that have occurred 

despite this decree, mankind has also had to deal with another, 

similarly important issue: What to do with the chemical 

weapons that already exist? These arsenals of doom harbour a 

great potential of danger in more ways than one. Their use on 

humanity is of course the primary risk. However, the improper 

storage of such weapons is no less dangerous. Environmental 

catastrophes of unimaginable scale loom on the horizon. 

Large caches of chemical weapons are still in storage across 

Eastern Europe and the former Soviet Union. In 2006, several 

German companies helped to establish special facilities for 

the demolition of chemical weaponry in the Russian cities of 

Kambarka and Potchep. Each of these plants prepares up to 

1.000 kg/h of reactive matter for incineration. Special technology 

provided by WATZ Hydraulik is in operation at both plants. The 

Stuttgart-based company Eisenmann AG is known to be the 

world’s leading system supplier of surface, environment and 

process technology. Their expertise in constructing facilities 

for exhaust air and waste water treatment and, in particular, 

thermal recycling and disposal of waste materials, is of primary 

importance in the disposal of chemical weapons. For these 

aforementioned applications, Eisenmann supplies a variety 

of technically sophisticated components, including explosion 

chambers, state-of-the-art robotics for transporting chemical 

warfare agents and special ovens in which nerve gas is safely 

incinerated. Many of these plants also feature components 

supplied by WATZ Hydraulik. In this field, the smallest error 

can lead to great catastrophe. The companies charged with the 

demolition of these weapons and the manufacturers of the 

machinery in use therefore rely only on those components 

suppliers able to guarantee the highest-possible product quality. 

That is why Eisenmann relies on hydraulics products made by 

4 | 5


WATZ Hydraulik. Due to the very special circumstances of the 

project, WATZ was integrated in the planning and construction 

phases from the very start. Working closely with Eisenmann’s 

development department, WATZ was able to develop optimum 

solutions for this highly sensitive area of application. WATZ 

provided the entire hydraulics station for the shuttle kiln. The 

power unit, installed on a special platform, was charged with 

opening and closing the shuttle kiln’s lift gates, which weigh 

some 18,000 kilograms. Each lift gate is operated by a separate 

power unit. To ensure operating safety, the power units are 

switched to the alternate lift gate. 

The lift gates themselves are raised and lowered by a 

special chain hoist. When lowered, the lift gate touches down 

on special rollers and is then pulled up to the furnace chamber 

by way of additional horizontally installed, unidirectional 

cylinders. This towing action must occur under a specifically 

predetermined amount of pressure, as the incineration 

process can potentially cause an increase in pressure of up 

to +300 mbar. Special safety valves prevent excess pressure 

inside the chamber. Furthermore, pressure reservoirs have 

been integrated to prevent pressure peaks. In the very unlikely 

event of hydraulic system failure, full closure of the lift gates 

is nevertheless guaranteed. Moreover, the gates are also 

protected against sudden collapse caused by an unforeseen 

loss of pressure, as it is possible to open only one gate while 

the system is in operation. 

With all of these measures in place, this WATZ system is 

able to guarantee maximum operational safety. Not bad for an 

application that is in use on 350 days a year, with three shifts per 

day! WATZ technicians were naturally on hand during system 

start-up and visit the site regularly for service and maintenance 

calls. System documentation was made available to the client 

in Russian, English and German language. 

Pictures: Eisenmann AG 

Innovative core sand treatment for foundries 

Successful plant engineering companies 

rely on hydraulics from WATZ 

More than 100 core sand treatment plants is a fact that 

speaks for itself: K & W is one of the most successful plant 

engineering companies in this field and its reputation has been 

built on quality and constant innovation since its beginnings 

in 1907. Its product offering ranges from individual casting 

machines to complete – fully or semi-automated – casting 

plant, including core sand treatment and regeneration. 

Casting machine performance ranges from 10 to 330 casts/ 

hour. In exactly the same way as Watz, K & W always focuses 

on meeting its customers‘ requirements. For this reason, 

the casting plant is always tailored to the customer‘s special 

needs. The average technical availability of K & W is over 

98%. High-precision humidity control and weighing equipment 

together with robust cooling and mixing design 

ensures a consistently high level of sand quality. All K & W 

products are characterised by innovation, expertise and 

experience combined with sound, high-quality design. And 

in order to provide its customers with the trusted high quality 

in all areas of plant engineering, K & W also relies on hydraulic 

systems from WATZ. 

This is true for its projects all over the world. In Brazil, for 

example, it built a modern casting facility for an automotive 

components supplier which has been manufacturing motors 

and clutch systems for many well-known car makers in 

Curitiba/Paraná Brazil ever since. WATZ supplied the hydraulic 

power systems for this project. The equipment supplied 

includes hydraulic power units with a tank volume of up to 

32,000 litres.


WATZ hydraulic systems meet royal requirements 

Perfect china demands 

perfect engineering 

Ceramic production is one of humankind‘s oldest cultural skills. 

The combination of time-proven knowledge and the use of 

state-of-the-art technologies make it possible to produce the 

highest quality ceramics. This is what Eisenmann AG, based 

in Böblingen, stands for. Eisenmann is a leading international 

system provider in the areas of surface finishing, material 

flow automation, ceramics, thermal process engineering and 

environmental technology and employs some 2,600 people 

in its many locations in USA, Mexico, Brazil, United Kingdom, 

France, Spain, Italy, China and Thailand. Eisenmann supplies 

complete firing lines for chinaware and sanitary ceramics 

with fully automated material flows from the moulding 

operation right through to sorting and packing. Well-known 

customers such as the Königliche Porzellan-Manufaktur 

depend on quality made by Eisenmann. In order to meet the 

high demands of its end customers, Eisenmann relies on 

components from Watz Hydraulik in its kilns and machinery 

such as spray-glazing facilities and driers. For Eisenmann AG, 

the name Watz Hydraulik stands for professional know-how, 

leading-edge technology and customer-focused service and 

guarantees the optimum result for every end customer. 

Pictures: Eisenmann AG 

6 | 7


Hydraulics for forming technology 

Precision 

teams up with 

performance 

The highest possible precision is the essential prerequisite 

for achieving lasting success in the components supply 

industry. Schuler AG, with its headquarters in Göppingen and 

18 further locations on three continents, is a technology and 

global market leader in forming technology and puts its full 

trust in the quality of the products supplied by Watz Hydraulik. 

Watz Hydraulik supplies Schuler, for example, with standard 

cylinders in all sizes together with the corresponding special 

equipment. Special cylinders in Schuler machinery, for example 

built in the form of telescopic cylinders, also come from Watz 

Hydraulik. A hydraulic drive unit designed to provide power 

to a forming machine using cold forming technology was 

supplied to the end user AUDI AG. The hydraulic power unit 

is built on a walk-on platform (in accordance with accident 

prevention safety regulations). The mechanical cutting 

and forming machines from Schuler, equipped with parts 

supplied by Watz Hydraulik, meet any challenges made on 

them such as increasing quantities, complex part geometry 

and processing high-strength materials. The pressing forces 

exerted by the machines range from 2,000 to 30,000 kN. 

Watz Hydraulik and Schuler – a strong partnership for 

innovation and the highest quality. 

Pictures: Schuler AG


Bending and forming technology 

Providing seemingly 

impossible solutions 

This is the brand 

promise of transfluid ® 

Maschinenbau GmbH. 

A promise that the tube 

processing specialists from 

Schmallenberg have to honour 

every single day. Over the last 20 years, 

transfluid ® has established itself as the 

leading manufacturer of pipe bending and end 

forming machines in the market. Once a mediumsized 

company, the transfluid ® brand of today has become 

a future-oriented global player. Wherever tubes are bent, cut 

formed or cleaned in the world – transfluid ® is never far away. 

„We are proud to have supported transfluid ® in this success 

story for more than 20 years“, says Horst Watz, Managing 

Director of WATZ Hydraulik GmbH, based in Lollar near 

Giessen. The two companies have enjoyed close cooperation 

for all of these 20 years. WATZ mainly supplies hydraulic 

power units and differential cylinders (in special sizes). The 

products have been developed and improved on the basis 

of many years of experience. What is special in this is that 

WATZ manufactures many of these products especially for 

transfluid ® in series and thus supplies customised equipment 

from series production. Nevertheless, some special power 

units and cylinders for tube bending pilot projects are supplied 

custom-made. One example is the end customer Deutz. The 

specially designed and produced tube bending plant was 

assembled directly in the factory. 

The power units required were 

produced by WATZ in 

close cooperation with 

transfluid ® and in accordance 

with the end customer‘s 

individual specifications. A 

further example is MJ Gerüst 

GmbH, a well-known German 

producer of scaffolding systems. The 

plant from transfluid ® is installed as stationary 

equipment in the factory and performs work in the areas of 

clamping, bending and stamping. An appropriate hydraulic 

system was designed and supplied by Watz for this. 14 

devices (clamping and forming cylinders) are controlled and 

supplied with power via a system connection from a central 

power unit. The hydraulic power unit is equipped with all the 

extras required: reservoirs to reduce pressure peaks and 

absorption of fluctuations in pressure and volume flows. 

Daisy-chained mounting subplates favoured by Watz ensure 

that valves can be replaced quickly and easily. transfluid ® has 

good reason to rely on the quality supplied by Watz Hydraulik. 

Once more, long-standing and above all trusting customer 

relationships always pay dividends. transfluid ® and WATZ 

Hydraulik have proven this in many projects – both nationally 

and internationally. 

Picture: transfluid ® Maschinenbau GmbH 

8 | 9


On the doorstep 

Why seek 

far afield ... 

Good partnerships can also often be found on one‘s very 

own doorstep. A good example is the firm Howial in 

Reiskirchen. The company, a manufacturer of special 

machinery for wood processing, is located in the immediate 

neighbourhood of WATZ Hydraulik‘s headquarters. It has 

been manufacturing finger-jointing machines near the 

university town of Giessen for over 30 years. The family-run 

company, now in the third generation, plans and develops 

a full range of finger-jointing machinery. The Howial name 

stands for reliability, high performance, intuitive operation 

and robust design. This accords with the demands for 

quality that WATZ Hydraulik also places on its product range 

Both companies are also owner-managed and have an 

international focus. It is therefore not surprising that these 

two neighbours have sought out and found each other. 

Picture: Howial 

Customised lightweights 

High performance in the smallest space 

Hürner Schweißtechnik – stands for innovation, 

performance, customer focus and operational safety with 

a widespread network of competent partners around the 

world. The company has been in the business of developing, 

producing and marketing products for plastic pipe joining 

for more than 25 years. The demands for premium quality 

that Hürner Schweißtechnik places on itself and on its 

services can only be met by incorporating first-class 

products in all its equipment and machinery. This is the only 

way to ensure the end customer‘s long-term satisfaction. 

Hürner Schweißtechnik GmbH is well aware of this and 

therefore depends on products from Watz Hydraulik in its 

equipment. Special miniature power units from Watz have 

been incorporated into the portable welding units that are 

used by Hürner GmbH. What is important in this is that 

all important valve functionality of the pressing and drive 

unit is implemented compactly and with no loss of quality 

in the control or valve block. And of course, the design 

of the units may not exceed a certain format and weight 

in order to ensure that the equipment in which they are 

used remains mobile and portable. Watz Hydraulik took 

up this challenge and has developed a series product 

that exactly matches the wishes and requirements of the 

customer, Hürner Schweißtechnik. Flexible solutions for 

any requirements without compromising reliability and 

quality – Watz Hydraulik makes it possible.


Hydroelectric power plants in Asia 

When large quantities 

of water 

need to be moved 

VAG GmbH moves water – on any scale. The Mannheim 

company is a manufacturer of innovative and reliable valves. 

Its product range includes state-of-the-art technology in the 

treatment of water and waste water together with many 

customer-specific solutions. Wherever water is treated, 

moved, stored and distributed, VAG gate valves and butterfly 

valves, plunger valves and hollow-jet discharge valves, air 

release valves, control valves and hydrants play an important 

role. Durability and decades of operational reliability matter. 

Repairing or replacing valves that often weigh several tonnes, 

such as those used in dams, is very costly. The supply and 

distribution of water and the treatment of waste water are 

very demanding operations. Valves must be able to withstand 

high water pressures and extreme temperature and weather 

conditions, irrespective of whether they are used in a desert 

or tropical climate. WATZ Hydraulik supplies the right solutions 

for even these most demanding scenarios. As VAG GmbH‘s 

partner, the Central Hessian company is supplying hydraulic 

units for two projects currently under way in Indonesia and 

China. WATZ is supplying a complete hydraulic unit for the 

construction of a hydroelectric plant in Indonesia. The hydraulic 

power systems are primarily intended to drive and control the 

hollow-jet discharge valves installed. The discharge valves are 

controlled via the turbine‘s oil hydraulic system. Should the 

turbines fail, the valves will open by themselves within four 

seconds at the most. This prevents pressure peaks in the 

system. The type ZM differential cylinders supplied are capable 

of pressures of up to 250 bar and operate synchronously. The 

cylinders of course have the necessary corrosion protection. 

Reliability and safety are the key requirements in this project 

relating to sluice-gate operations for the 150 km Asahan river 

in Indonesia. 

Pictures: VAG Armaturen GmbH 

10 | 11


Hydraulics for drilling specialists 

Where black 

gold gushes 

The company ITAG was founded back in 1908 and today 

employs some 550 people. The ITAG engineering works are 

primarily engaged in the manufacture of equipment for the 

for the oil and gas industry such as ball valves, drill string 

components and wellhead systems. ITAG products are used 

all over the world in the production of oil, gas and geothermal 

energy. ITAG also performs drilling and workover services for 

its customers. It is in this area in particular that hydraulic 

technology made by WATZ Hydraulik is used. 

The Central Hessian hydraulics specialist supplies, for 

example, complete hydraulic power units for ITAG‘s drilling 

rigs. What is special about the equipment is the way in which 

the technology is powered. The power units are installed 

in easily transportable sound-insulated containers and 

comply with the strict ATEX directives governing electrical 

and mechanical equipment used in potentially explosive 

atmospheres. This is particularly important with regard to the 

equipment‘s specific use. When drilling down into the earth, 

underground gas-bearing formations may be encountered. 

Depending on the installation site, escaping gas could 

enter the container. Moreover, performance loss due to the 

distance to the hydraulically-driven devices must be avoided. 

The container is equipped with two power units, with one 

of the two 210 l/min units in constant operation while the 

second is ready to run in standby, this covering any outages. 

The complete motor-pump unit is mounted on a carrier plate, 

and the unit can be raised with the help of a double-action 

cylinder using a manual pump. This makes any future repair 

or maintenance work in the container much easier. 

ITAG attaches great importance to innovative solutions for 

its components, flexible management, highly qualified staff 

and of course reliable components suppliers. For this reason 

WATZ Hydraulik is justifiably proud of having ITAG among its 

customers. 

Picture: ITAG GmbH


Tradition since 1872 

Rings and wheels for the 

automotive industry 

Rolling rings and wheels requires special technical and 

technological competence. The roots of the SMS Meer 

Group stretch back to the year 1872. Sufficient time in which 

to develop above-average competence and appropriate 

expertise. The Group is nowadays one of the world‘s 

leading plant manufacturers, and the SMS Meer name is 

well known in the steel, copper and aluminium industries. 

SMS provides a complete range of products and services: 

comprehensive expertise is provided from the initial layout 

to the completed ring and wheel rolling mills. Hydraulic 

engineering from Central Hesse is very much in demand for 

the implementation of individual projects. WATZ Hydraulik 

designs and manufactures complete hydraulic power units 

with large tank capacities for SMS. The most recent delivery 

consisted of a WATZ power packet – a hydraulic power station 

comprising power units with 400, 800, 160 and 630 litres 

capacity respectively. SMS installed the power station for 

one of the world‘s largest automotive components suppliers. 

These power units provide the customer, a manufacturer of 

components for diesel and petrol injection pumps as well 

as gearboxes and engines, with the power to drive pressing 

equipment and ejectors reliably. Picture: SMS Meer GmbH 

12

Sollte hier auch was stehen? 


Technical Data 

Medium: 

sea water 

Flow volume: 760 m 3 /h 

Filtration grade: 100 μm 

Design pressure: 13.8 bar 

Design temperature: 60 °C 

FAUDI for CNOOC 

Clean sea water thanks to 

automatic backflush filters 

The China National Offshore Oil Corporation (CNOOC) is 

China‘s third largest petroleum company. It runs large 

cooling systems with sea water in its plant and machinery. 

Depending on where the plant is located, this process water 

can be contaminated in all sorts of ways, e.g. by algae, 

shells or gravel and stones, resulting in unwanted deposits 

and blockages in the downstream plant sections, heat 

exchangers and pipes. In order to avoid this, CNOOC relies 

on continuous-operation filtration systems from FAUDI such 

as the fully automated Type 30 backflush filter. The backflush 

filter is cleaned without interrupting operations by using part 

of the flow of the clean flow medium. Each of the installed 

filtration elements is flooded one after another in the reverse 

flow direction, and the dirt that has been deposited on the 

filter surface is removed and rinsed away. The optimum 

product characteristics of the Type 30 automatic backflush 

filter from FAUDI were the arguments that convinced the 

CNOOC to cooperate with FAUDI. This filtration system 

represents qualities such as reliability and robust design with 

low running costs and no maintenance. 

12


FAUDI for Andasol 

Protected solar power 

in Spain 

Andasol 1 to 3 are located in the Spanish province 

of Granada, with Andasol 3 still under construction. 

They are state-of-the-art solar-thermal power stations that, 

following completion, will consist of 510,000 square meters 

of collector surface - Europe‘s largest solar power station. 

The technically usable potential of solar-thermal electricity 

generation exceeds the worldwide demand for electricity 

many times over. Solar radiation heats up oil as a heat 

carrier to approximately 300 °C, which is then pumped to 

circulate through the system and transfer the energy. In this 

process, very fine particles develop, which are deposited 

on the insides of the piping and which can cause damage. 

To prevent this, candle filters with special stainless-steel 

backflush filter elements from FAUDI are used in Andasol 1 

and 2. The special design of these HTF filter elements means 

that, when the backflush valve in the lowest part of the filter 

is briefly opened, dirt is washed out of the filter elements 

and discharged from the system. This serves to protect the 

sensitive machinery from dirt and suspended particles in the 

optimum way. The filters achieve a filtration grade of up to 3 

μm. The newly developed gas-assisted backflushing process 

and the newly developed filter elements in the FAUDI candle 

filters also reduce flushing loss considerably. This protects 

the environment through less waste and also allows financial 

savings to be made due to lower amounts of expensive oils 

being lost. Besides Andasol, FAUDI candle filters are also 

used in Spain in the Extresol power stations 1 and 2. 


Medium: 

heat carrier oil 

Design pressure: 18.5 bar 




10 | 11

Inside Filtration – The Official FAUDI Newsletter 

FAUDI for BPCL 

Sophisticated catalyser 

protection 

Depending on requirements and the process used, 

hydrocarbons from the feedstock products are cracked 

and further treated in a reactor with a catalyst bed. If impurities 

such as coke particles, rust or other metals are deposited in 

the reactor, the whole process could be impacted. Influence 

on the speed of the reaction, an increase in the differential 

pressure, poor liquid distribution in the catalyser and, above 

all, long downtimes for the expensive catalyst plant are 

only some of the possible consequences. It is therefore 

important to avoid these negative and costly effects. A highperformance 

filtration system from FAUDI is the solution. And 

there is a good reason for this: as a leading filter manufacturer, 

FAUDI can look back on 70 years of company history that 

includes many technical innovations and patents. Many oil 

refinery operators therefore rely on FAUDI filter technology. 

Bharat Petroleum Corporation Limited (BPCL), one of India‘s 

highest-turnover companies, puts it faith in modular filters 

from Stadtallendorf. This range of modular filters is a system 

designed to filter hydrocarbons and runs automatically, 

almost maintenance-free and above all with no filter material 

consumption. Cleaning is effected automatically, with the 

candles in the filter being flushed in the reverse direction of 

flow – without interruption to the filtration process. Thanks 

to its modular design, large flow volumes can be handled. 

It is also possible to extend the filter systems in a variable 

way. This ensures that a customer-specific extension can be 

added to the plant while keeping costs under control. BPCL 

trusts the filters made by FAUDI and secures competitive 

advantage for itself by reliably protecting the catalyst beds 

from contamination and improving cycle times. 


Medium: 

vacuum gas oil 



Design pressure: 25 bar 

Design temperature: 340 °C


FAUDI for Shell GmbH 

The fascinating inner-life 

of an ocean giant 

Tankers fascinate people due to their huge size. It is not 

apparent at first sight that in the interior of the giant ship 

finely tuned and elaborate mechanisms must operate in 

order for loading and unloading to be performed smoothly. 

For example, in the final stage of unloading, large quantities 

of air are fed through the pipes. This must be separated out 

of the liquid flow before it passes the measuring devices. 

Here, everything depends on the highest possible precision 

and reliability of the technologies used. In its tankers, Shell 

GmbH uses gas separators from FAUDI, which, in addition 

to having approval by the weights and measures authorities, 

guarantee the performance of the gas separation and also 

require no maintenance. By constantly measuring the fill 

level, the system prevents the level of liquid from sinking 

to a critical point, and pressure blows can be intercepted. 

Besides helping in the unloading of tankers, FAUDI gas 

separators are used in many systems for transferring aviation 

fuels, petrol and other hydrocarbons. 


Design pressure: 25 bar 



Air throughput: max. 2,200 m 3 /h 

8 | 9


FAUDI for MTU Aero Engines 

Global players 

welcome 


Filter surface: 7.5 m 2 

Filtration grade: 

Feed quantity: 

Design pressure: 

30–50 μm 

Operating temperature 

of coolant: 22 °C 

Container (steel): 

2100 l/min and 2200 l/min 

12 bar an WZM 

approx. 19,000 l 

How can the exacting demands of a global player with 75 

years of history be met - one which also happens to be 

number one worldwide in the independent servicing of civil 

aviation engines? MTU Aero Engines is one such company. It 

develops, manufactures, services and repairs jet engines for 

the civilian and military markets and has achieved a leading 

position in this field of engineering. In addition to several 

locations in Germany and a number of global partnerships, 

MTU has had a manufacturing facility in Rzeszów in Poland 

since the beginning of 2009. Two FAUDI vacuum filters are 

used for the required processing of the cutting fluids for 

two processing lines used to machine nickel-based alloys, 

high-alloy steels and titanium. The floor-based systems 

serve as the central units for supplying groups of machines 

comprising six and four grinding machines respectively. 

Filtration is effected using non-woven fleece in order to 

achieve the required filtration grade of 30 μm. A control 

system programmed by FAUDI ensures that all elements 

and power units interact reliably with each other. In order to 

guarantee the assured availability of its plant over the long 

term, MTU puts its trust in the many years of experience 

in planning, design and manufacturing that FAUDI can look 

back on. The expertise and product quality of FAUDI GmbH 

provides MTU Aero Engines with the basis for a successful 

and dependable partnership. 

Picture: MTU Aero Engines


FAUDI for Continental, South-East Asia 

Quality for any demand 

Germany‘s second largest tyre manufacturer, 

Continental AG, sees great potential in the South 

East Asian region. As a result, the company decided to 

set up a new production facility in Thailand. It has been 

producing components for diesel fuel injection systems 

there since the beginning of 2009. Continental ordered 

two central coolant processing systems in order to set up 

the new production operations. The „soft“ production area 

is supplied by a FAUDI FUF 22 vacuum filter unit (main 

filtration) and an AS 18 pre-coat filter unit (bypass filtration) 

while the „hard“ production area is supplied by FAUDI 

Type AS 34 twofold pre-coat filters (that can be extended 

up to fourfold). 

Parts made from cast metal are processed on the soft 

milling machines. A FAUDI vacuum filter with relatively 

high-quality filter fleece was chosen as the filtration 

solution for the machining oil, which is required in filter 

quality NAS 12. This ensures that high filtration quality and 

a filtration grade of approx. 30 μm are achieved even with 

new fleece, i.e. without filter cake. The pre-coat filter in the 

bypass also prevents very fine particles from collecting in 

the machining oil. 

In hard machining, i.e. steel grinding, a low-viscosity 

grinding oil with a very high filtration of contamination 

class NAS 6 is required as coolant. The ideal solution here 

is a pre-coat filter system made by FAUDI – the candle 

filter allows deep-bed filtration and thus a high filtration 

grade. The filter elements are also protected from lasting 

contamination through the fact that a deposit layer 

develops on the filter candles that is then cleanly removed 

thanks to a specific difference in pressure. The dirt is then 

finally discharged from the system in a so-called sludge 

treatment process. Continental sees FAUDI GmbH as a 

competent and reliable partner for whatever demands that 

have to be met. 

6 | 7


FAUDI for Continental, Eastern Europe 

Clean performance 

for a clean emulsion 

Eastern Europe is growing very rapidly as an automotive 

region. Continental AG opened a new production facility 

in Zvolen in the Slovak Republic in 2005 in order to keep 

pace with this development and to retain its international 

competitive edge. It is intending to expand the new factory 

in Zloven to become one of the largest facilities for the 

manufacturing and assembling of brake callipers. FAUDI 

equipment is increasingly being used in the location‘s 

16,000 square metre production area, e.g. a coolant cleaning 

and supply plant with sediment tank and backflush filters. 

This supplies 11 cutting machines with a total capacity of 

8,000 l/min. The required filtration grade is 60 μm. In order 

to achieve this, the feed emulsion is first pre-cleaned in a 

sediment tank and subsequently pumped through three selfcleaning 

backflush filters. These are equipped with split-pipe 

filter elements made from stainless steel and are backflushed 

by the pressure in the system using clean emulsion. The 

backflush liquid is then cleaned once more with a vacuum 

filter. This combination of various filter systems ensures safe 

supplies of clean emulsion to the machining equipment. 

Continental AG has great expectations of its location in Zvolen 

and puts its complete trust in products made by FAUDI.


Berndorf Band GmbH 

Endless belts for projects 

all over the world 

The Austrian company Berndorf Band GmbH has been 

manufacturing endless steel bands since the beginning of 

the 20th century. A subsidiary of Berndorf AG, the company 

takes stainless steel, carbon steel and titanium and turns 

them into high-precision processing and conveyor belts. 

This Austrian company has built up a reputation around the 

world in the development and manufacture of endless steel 

belts. The products developed and produced by Berndorf 

Band GmbH can be found around the world, with exports 

accounting for over 90 % of production. 

Berndorf attaches great importance to the highest 

precision in all areas of its work. Innovative and sustainable 

solutions are also required when it comes to recycling 

and disposing of the waste products that result from the 

production process such as grinding slurry and swarf. 

FAUDI provides Berndorf with such a solution in the form 

of a hydraulic briquetting press. Waste materials that 

contaminate the coolant during the grinding and rolling 

stages are separated from the actual coolant using a 

briquetting press and an extruder allowing the liquid to be 

fed back into the coolant process. 

The advantages can be seen in the distinct savings 

in new coolant and also in the possibility of recycling the 

filtered residues such as swarf, which are sold to waste 

disposal companies. In addition to these advantages, the 

high quality of FAUDI products and the volume reduction 

result in a lower handling overhead. 

The press, working 24 hours a day throughout the year 

generally pays for itself within 18 months. It is therefore not 

surprising that Berndorf relies on products made by FAUDI. 

Picture: Berndorf Band GmbH 


Component: 

Processing: 

Coolant: 

Type of swarf/slurry: 

Operational: 

Project volume: 

Residual content of 

coolant sludge: 


coolant sludge: 


coolant briquette: 

Briquette properties: 

stainless steel belts 

grinding, rolling 

emulsion 

broken swarf mats 

12 months/year 

22 working days/month 

24 hours/working day 

355 kg/h 

approx. 55 % after predemoisturising 

extrusion 

230 kg/h 

approx. 30 % 

approx. 6 % 

Ø = 95 mm 

L = approx. 80 mm 

Density = approx. 5.1 kg/dm 3 

4 | 5


FAUDI for Petrobas 

Maximum performance – 

minimum filtration loss 

One of the world‘s largest oil companies, Brazil‘s Petrobas 

S.A., uses filter units from FAUDI in its REVAP refinery. 

The fully-automatic and maintenance-free FAUDI modular 

pump units are used in refineries to filter hydrocarbons. 

Low-molecular hydrocarbons, rust and metal residues are 

produced during the cracking processes that take place 

in the refineries; these can damage the catalyst units. In 

order to prevent this, a cleaning process using modular filter 

systems must take place. However, this results in medium 

being lost through flushing as it has to be used for flushing, 

or an external medium has to be used. By using gas-assisted 

backflushing, a maximum amount of filtrate can be obtained 

without losing the medium itself through flushing. It is 

this technique that is used in FAUDI‘s modular filter units. 

During cleaning, the individual modules are first flushed with 

medium or external medium and a gas buffer is then fed into 

the module. Medium flushing loss is reduced to a minimum 

since the modules no longer need to be fully flushed with 

medium or external medium. The inert gas used in the 

backflushing process is separated from the medium using a 

gas separator. Petrobas is a technological leader in offshore 

production and puts its complete trust in FAUDI‘s high level 

of technical expertise in order to maintain this position.


Contents 

Imprint 

3 Using instinct and 

entrepreneurial thinking to 

become “Local Hero - 

Mutmacher der Nation” 

4 Endless belts for projects 

all over the world 

FAUDI GmbH 

Scharnhorststrasse 7 

35260 Stadtallendorf 

Telefon +49 (0)6428 702-0 

Telefax +49 (0)6428 702-188 

info@faudi.de 

www.faudi.de 

5 Maximum performance – 

minimum filtration loss 

6 Quality for any demand 

7 Clean performance for a clean 

emulsion 

8 The fascinating inner-life 

of an ocean giant 

9 Global players welcome 

10 Protected solar power in Spain 

11 Sophisticated catalyser 

protection 

12 Clean sea water thanks to 

automatic backflush filter 

2 | 3


Far left: Horst Watz, “Local Hero – Mutmacher der Nation 2008” 

Courage and gut feeling – a good combination 

Using instinct and entrepreneurial 

thinking to become “Local Hero – 

Mutmacher der Nation” 

Germany needs role models - people with optimism and 

ideas that inspire. For this reason a top-class jury with 

Lower Saxony‘s Premier, Christian Wulff, as patron awards 

an annual prize to „Local Heroes - Mutmacher der Nation“. 

The prize recognises entrepreneurs from small and mediumsized 

companies who have shown exceptional and exemplary 

entrepreneurial spirit and determination. 

In 2008 Horst Watz, Managing Director of both WATZ 

Hydraulik and FAUDI GmbH received the prize for an 

outstanding entrepreneurial decision. In May 2006, Horst 

Watz bought the insolvent FAUDI GmbH in Stadtallendorf. 

The company, numbering 80 employees, was founded in 1938 

and is one of Germany‘s traditional companies, operating in 

the field of filtration technology. However, the once number 

one address in the field of coolants and process engineering 

got into great difficulties as a result of mismanagement and 

the changing economic situation. Following the instigation 

of insolvency proceedings, the company faced being sold 

off and broken up. Competitors were already expressing 

interest in the company‘s patent rights. Horst Watz decided 

to purchase the company just 24 hours before the bidding 

deadline expired. Through this decision – as he himself calls 

it, a gut decision – he saved 80 jobs and a medium-sized 

company with a long tradition. The purchase price of 1 million 

euros was financed by his own company, WATZ Hydraulik 

GmbH, with start-up financing of a further 3.5 million euros 

being secured by private guarantees. 

Horst Watz has not regretted his courage and his (gut) 

decision. On the contrary: „At the end of the day it was a 

question of a traditional German company and its people,“ 

relates the businessman. He continues, „Some people say 

that such a decision requires courage. That may be. But I 

just knew what the potential of the company and above 

all of its people was.“ Insolvency is no longer an issue for 

FAUDI. Turnover in 2007 amounted to eleven million euros 

and increased significantly in 2008 to 14.5 million euros. The 

number of employees has now grown to 85, including 12 

vocational trainees who will all complete their training with 

flying colours.

Issue 1 / 2009 / www.faudi.de 

Inside Filtration 

The Official FAUDI Newsletter 

Clean filtration 

technology

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