hydraulik - HANSA-FLEX Hydraulics Canada Inc.

04/08 

Issue 04/2008 

 

HYDRAULIKPRESSE 

The adventure begins 

The XWORLD Tour is on its way 

Page 4 

08 

14 

18 

Fired up about 

heavy diesel 

Precision work at 1350 

degrees 

HANSA-FLEX 

Thailand 

Sights set on expansion 

Everything shipshape 

for the magnificent 

“AIDAbella” 

Preventative maintenance 

on the gateway 

to the North Sea


CONTENT | IMPRESS 

Content 

Editorial 03 

XWORLD: Starting signal for a world of adventure – Get on board and the fun will start 04 

As you like it – Offroad or the more comfortable option? 05 

One connector, one programme – The best connections in Blomberg 06 

Fired up about heavy diesel – Precision work at 1350 degrees 08 

For moving moments – Line engineering for large marine diesel engines 10 

But with cream please! – Expert filling for a versatile range 12 

HANSA-FLEX Thailand – Sights set on expansion 14 

Augsburg branch: the concept artists – Quick start with OilQuick 15 

Precision wheels from the coalfields– Baptism of fire 16 

Everything shipshape for “AIDAbella” – Preventative maintenance on the gateway to the North Sea 18 

The new way – Further training as hydraulics specialist (HWK) 20 

Training seminar schedule 20 

IHA expands further training – Foundation stone for a milestone 21 

In conversation with Joachim Foltan: “Ultimately it is a focus on service and sympathy that count” 22 

The new BGR 237 is on its way – Focus on practice 24 

More than just a technician – Axel Tammen takes a global view 26 

Quiz, Figures & Facts, Preview 27 

Editor: 

HANSA-FLEX Hydraulik GmbH 

Zum Panrepel 44 · 28307 Bremen 

Germany 

Phone: 0421 - 48 90 70 

Telefax: 0421 - 4 89 07 48 

E-Mail: info@hansa-flex.com 

www.hansa-flex.com 

Compilation: Dietbert Keßler, Enrico Kieschnick, 

Horst Otto (PAPP Werbeagentur) 

Layout: N. Staciwa 

Print: Berlin Druck · www.berlindruck.de 

Responsible for contents: Wolfgang Rink 

Frequency: Bimonthly 

Subscribe to the 

on our website. 

02 


AUSGABE ISSUE APRIL 2008 

14. JAHRGANG

FOREWORD 

H 

Editorial 

Dear reader, 

The starting signal has been given: the XWORLD Tour has set off! On 9 March the convoy of Toyota Land 

Cruisers left HANSA-FLEX’s head office in Bremen, accompanied by the escort vehicle. Sporting magnificent 

paintwork, these vehicles are equipped for whatever tough offroad adventures they may encounter. This 

tour, whose highlight will undoubtedly be the visit to the Olympic Games in Beijing, is not just an amazing 

experience for all participants and offroad fans, but also a major event for HANSA-FLEX. The journey through 

two continents signals our international claim to be a hydraulic service-provider and system partner while 

underlining the steady growth of the company. We hope that everyone taking part has a good trip and are 

already looking forward to reading the interesting reports that will appear in HYDRAULIKPRESSE. 

In contrast, one topic that sounds a lot less spectacular is the change in the standards laid down by the 

employers’ liability insurance association. But something that is so functional as the new BGR 237 regulation, 

which provides rules for the safe usage of hydraulic hose lines and is scheduled to come into force this 

summer, has previously been the subject of intensive and often controversial debate on advisory boards and 

specialist committees. HANSA-FLEX is involved in many such working groups as we are aware of our responsibility 

for man and the environment and strive to live up to it. With this objective in mind, HANSA-FLEX 

training manager Ulrich Hielscher has drawn on his immense knowledge when creating the new practical 

guide for the proper handling of hydraulic hose lines. This way we are doing our bit to update standards in 

the hydraulics sector. In an interview on page 24 Ulrich Hielscher explains what BGR 237 actually means in 

practical terms. 

Such engagement in boards and committees forms part of the responsibilities of a system provider for fluid 

technology, a role HANSA-FLEX has meanwhile taken on. It is thus not surprising that Axel Tammen also 

has plenty of experience to offer in national and international standardisation committees. Last year this 

graduate engineer was appointed by HANSA-FLEX to the new position of “General Manager Technology”, 

a role which in his view consists of acting as the go-between for technology and sales - including for our 

customers. On page 26 of this issue he tell readers how he wants to ensure that the Technical Department 

is involved more closely in the overall development of the company and why this will help to improve customer 

satisfaction. 

The Management Board 

Uwe Buschmann 

Thomas Armerding 

ISSUE APRIL 2008 


03


XWORLD 

XWORLD: Starting signal for a world of adventure 

Get on board and the fun will start 

cope with anything. The level of comfort offered by 

these cars makes driving even more enjoyable. 

Round the world four times 

At eleven o‘clock on 9 March 2008 the time had come: 

the procession of vehicles taking part in the XWORLD 

Tour pulled away from the starting line. The convoy 

of five brightly decorated Toyota Land Cruisers and 

the Toyota Hilux escort car set off with their crews for 

Istanbul from the yard of HANSA-FLEX‘s HQ. 

The participants were seen off at the head quarter 

of the HANSA-FLEX Group in Bremen by managing 

directors Uwe Buschmann and Diether Horst 

Seidler, who wished them lots of enjoyment on 

their exciting trip. “We see the XWORLD Tour as 

a good opportunity to present HANSA-FLEX as a 

company with an international flavour to it,” says 

Uwe Buschmann, once again underlining the motivation 

behind this adventure. “With the XWORLD 

Tour we want to bring people together, to promote 

understanding between them and to learn about 

other cultures. This is why we will also be stopping 

at HANSA-FLEX branches along the route on the different 

stages of the tour. Meeting the staff based 

there will offer particularly clear insights of how 

people live in the region visited.” 

Months before setting off, the expedition vehicles 

underwent tough testing to check their suitability 

for the tour: the Land Cruisers have been out and 

about on Europe’s roads since the spring of last year. 

The vehicles are fitted out with all conceivable extras 

and special offroad equipment such as snorkels 

for driving through rivers, search headlights and a 

cable winch. They have been customised in this way 

to offer participants maximum safety both on- and 

offroad while still enjoying the trip. In the months 

of preparation leading up to the tour, offroad 

fans were offered the opportunity to put the cars 

through their paces, as well as customers and employees 

of HANSA-FLEX and journalists from trade 

magazines. Their verdict was unanimous: Land 

Cruisers are great to drive on motorways and ordinary 

roads, but offroad they really come into their 

own. Whether faced with mud, steep terrain, roads 

full of potholes or river crossings, these vehicles can 

Besides the adventure of passing through 34 

countries on two continents, pleasure in driving 

also plays a key role. In 20 months participants 

will cover some 150,000 kilometres in 43 stages, 

a distance that is equivalent to four times round 

the earth! The longest stage, estimated to be 5,000 

kilometres, extends from Kashgar to Beijing and 

even the shortest, from Lhasa – the city of the Dalai 

Lama – to Kathmandu, is 1,300 kilometres. The trip 

takes in the sacred sites of Asia, Lake Manasarova 

and Mount Kailash. These two Buddhist sanctuaries 

are not normally accessible to tourists but XWORLD 

has been given permission to admire them. 

In their offroad vehicles participants will be passing 

through spectacular sites and fascinating landscapes. 

Every one of these stages represents an 

expedition with its own extraordinary route. 

Right at the start of the tour there is a very special 

offroad trip: On the first stage of the route, Bremen 

to Istanbul in 14 days, participants have to cross 

eight countries, driving right through the varied 

Balkan landscape, where they certainly won’t miss 

out on any fun. Every further stage has its own particular 

charms: Crossing the Carpathians towards 

4 

ISSUE APRIL 2008

XWORLD 

H 

Ukraine, Russia and China promises to be no less 

fascinating than the eleventh stage, the highlight 

of the adventure tour. This special section of the trip 

runs along the Great Wall of China, past the Buddhist 

cave temples of Yungang towards Beijing, 

where the programme includes a visit to the Olympic 

Games. Motorsport fans should not miss out on 

the 16th stage under any circumstances. After passing 

the Yangtze, Asia’s longest river, the convoy will 

arrive in Shanghai in time to witness the starting 

signal for the Formula 1 race. Stages 29 to 32 take 

participants over the mountain passes of the Himalayas 

to the base camp of Mount Everest. 

Stages 36 to 40 also promise to be an exciting experience, 

with all the variety the Russian landscape 

has to offer: the vast expanse of Siberia, home to 

the Russian Pacific Fleet in Vladivostok, contrasting 

with the big cities of Moscow and St Petersburg. 

Special delights, individual highlights and unforgettable 

moments – the different stages of the 

XWORLD Tour take in destinations that cannot be 

found in any other travel brochure. You can still sign 

up. Book now: www.xworld.cc 

Offroad or the more comfortable option? 

On the first stage of the XWORLD Tour Melina 

Lindenblatt and Matthias Göttenauer will be on 

board the escort vehicle as tour guides. The MD 

of the agency Pro+Motion responsible for organising 

the XWORLD event has many years of 

experience in such adventure tours. He also has 

a particular interest in the tourist destination of 

Istanbul, where the participants will arrive at 

the end of the first stage. 

Melina Lindenblatt has carefully planned all 

stages, even visiting China and Tibet herself to 

check the details of the trip and make the accommodation 

arrangements. But it is not possible 

to prepare for everything as “part of the 

fun on such trips is spontaneity,” comments 

Matthias Göttenauer. He has already experienced 

this himself and therefore also hopes 

that the participants in the XWORLD adventure 

tour will contribute their ideas and wishes over 

the different stages. 

The three people in the escort vehicle – Enrico 

Kieschnick will also be on board as 

HANSA-FLEX’s XWORLD Tour project manager 

during the first stage – want to see together 

whether the programme they have put together 

appeals to the entrants or whether 

changes will result in even greater enjoyment. 

For example, in terms of greater pleasure in 

driving: Should the percentage of offroad driving 

be stepped up? Are the different stages 

not too long for participants? And how does 

the vehicle equipment stand up during the 

tour? The three members of the escort team 

are hoping for answers to all these questions 

during the first stage, for as Enrico Kieschnick 

remarks, “we have put together a great package 

for offroad fans”. “The cars have already 

shown what they can do under tough test 

conditions. Entrants who take a more cautious 

approach will have no less fun and adventure 

than awaits the more sporty drivers taking the 

offroad routes.” 

According to Matthias Göttenauer “Participants 

can decide later on in the individual stages 

whether the next day for example they prefer 

to use more offroad routes or proper roads.” 

Even breaking down will hold no fears for 

entrants: if they are not able to cope with the 

problem themselves, the convoy can rely on 

Toyota’s round-the-clock service from its dense 

network of garages round the world. 

Matthias Göttenauer, Melina Lindenblatt and 

Enrico Kieschnick 


5


PHOENIX CONTACT 

One connector – one programme 

The best connections in Blomberg 

“A high level of vertical integration is our philosophy,” 

was the comment from Phoenix Contact, which 

added, “We therefore not only develop modern 

electronic applications but also use them ourselves 

in production.” One example of this is the optimisation 

of injection moulding machines designed to 

turn plastic parts into finished components ready 

for installation or destined for upgrading. Here it is 

a question of how to improve the control and processes 

of such machines to make them work even 

faster. The engineers from Phoenix Contact pass on 

such knowledge to their customers and continuously 

implement measures for retrofitting. Phoenix 

Contact sees itself as a service-provider which sells 

its concepts to third parties such as the car manufacturing 

industry, where individual automotive parts 

are moulded within seconds and then dispatched 

to the next station for further processing. Acting 

as a system partner for logistics and automation, 

Phoenix Contact has been highly successful in this 

sector and helps customers with development from 

the initial idea to application. 

Sure to be reliable 

It all started in 1928 with a modular terminal block 

that quickly established itself as the standard for 

power stations, industrial plants and buildings. Today, 

exactly 80 years later, Phoenix Contact offers a 

portfolio of industrial electrical products that range 

from the classical terminal block through machine 

connectors, electronic signal converters and surge 

protection to wireless Ethernet and industrial automation 

technology. This global player recently broke 

through the 1 billion euro sales mark. 

The company based in Blomberg uses four production 

plants in Germany and five international 

facilities to manufacture connecting elements 

such as PCBs and connectors for modern electronic 

engineering applications, so ensuring the best connections 

from sensors to control thanks to prefabricated 

modules. Such plug connections are used 

for example in the field of traffic engineering, the 

automotive industry, shipbuilding and mechanical 

engineering, for industrial communication in 

process technology and of course, as the standard 

in power plants. The standard of the green connector 

from Phoenix Contact ensures maximum operational 

safety whatever the sector. Phoenix Contact 

manufactures all connectors, plug connections, 

PCBs and terminal blocks in-house, using plastic 

materials together with injection moulding machines 

designed according to its own concepts. 

The injection moulding machines used by Phoenix 

Contact are subject to heavy workloads and operate 

virtually non-stop. Here high locking pressures of 

25 – 150 t ensure perfect functioning of these machines, 

so allowing them to produce precision parts 

of exactly the right shape. The tools used in such 

a machine open and close in a fast cycle, with the 

necessary flexibility being provided by hydraulic 

hose lines. In addition, the injection moulding tools 

are exposed to temperatures ranging from 60 – 200 

degrees C in the factory environment. 

In this context Phoenix Contact sets great store by 

operational reliability. It counts on HANSA-FLEX 

to rule out the failure of hydraulic hose lines and 

so prevent any loss of production. The hydraulic 

service-provider has supported the manufacturer 

in Blomberg for 20 years, initially from Boffzen until 

the company decided to look after this customer 

with the branch at Blomberg. As Phoenix Contact’s 

production plant is within sight from this branch, 

the company is always on hand to quickly respond 

to the customer’s needs at any time. When it comes 

to routine business such as mechanical engineering, 

HANSA-FLEX supplies the customer with hose 

lines, couplings, hydraulic precision piping and a 

6 


ISSUE APRIL 2008

PHOENIX CONTACT 

H 

personal advice service - a task which has been the 

responsibility of Vinzenz König for ten years. 

When injection moulding machines are involved, 

HANSA-FLEX can be relied on to ensure their operational 

readiness. By performing regular maintenance, 

it contributes not only to safety at the 

plant, but also staff safety. Phoenix Contact takes 

the precaution of replacing all hydraulic lines on 

machinery every six years, so complying with the 

recommendations of the employers’ liability insurance 

associations, insurance companies and classification 

societies. This means that it is protected 

from any rights of recourse. 

Fast fitting depends on careful 

preparation 

Vinzenz König teams up with Oliver Beckmann, 

head of technical maintenance and servicing at 

Phoenix Contact, to coordinate this work. Planning 

starts three or so months before execution to avoid 

any unnecessary downtimes for the production 

machinery. The “man from HANSA-FLEX” determines 

the exact requirements for hose material, 

fittings and screwed connections in advance so that 

the HANSA-FLEX mobile service centre can turn up 

later on with all necessary spares already on board. 

The service technicians manning the workshop on 

wheels manufacture the new hose lines according 

to samples and install them to produce a perfect 

fit. 

Such work also includes dismantling machine 

panelling and injection moulding units so the old 

hose lines can be removed. New ones are then 

manufactured according to samples and installed 

on the machinery. The first trial run is attended by 

a HANSA-FLEX service technician. The final step is 

to put the injection moulding machine back into 

production. 

HANSA-FLEX additionally provides the customer 

with PTFE corrugated hoses; only recently were 15 

machines retrofitted with such hoses. These PTFE 

hoses are subject to a temperature control cycle at 

approx. 200 degrees C. In this cycle the hoses transport 

the medium used for temperature control of 

the injection moulding tools in the machines. 

Like many other HANSA-FLEX customers, Phoenix 

Contact also has all new hydraulic hose lines it installs 

immediately marked with an X-CODE. As the 

data for every machine is registered by HANSA-FLEX, 

spare parts can be replaced quickly and easily with 

the help of the X-CODE. This also greatly facilitates 

job planning for the regular replacement of hose 

lines every six years as HANSA-FLEX can find out 

beforehand which spares are required with a click 

of the mouse. They can then be manufactured in 

advance, so significantly reducing the fitting times 

on site. A cost advantage that is systematically exploited 

by Phoenix Contact. 


HYDRAULIKPRESSE 7


MAN DIESEL 

Fired up about heavy diesel 

Precision work at 1350 degrees 

Anton Schweyer plunges the temperature sensor 

deep into the enormous foundry ladle. The thermometer 

reads 1350 degrees C for the metallic lava 

bubbling inside. The foundry expert is satisfied. He 

indicates his approval with a quick glance at his colleagues 

at the other three ladles and then gives the 

signal for casting. 

At the touch of a button the weighty containers tip 

forward simultaneously, pouring the red-hot metal 

into the casting mould with amazing accuracy. 

There’s no going back. The next 100 seconds will 

decide the quality of the crankcase produced from 

this fiery liquid. 

Every week an average of four large crankcases 

are produced at the foundry of MAN Diesel. These 

gigantic workpieces weighing many tonnes are 

the heart of the diesel engines manufactured at 

the company’s HQ in Augsburg. The biggest case 

for the 18V48/60 weighs in at 90 t, with 115 t of 

metal being melted for the casting process. Engines 

of this type deliver an output of 29,300 hp (21,600 

kW) and are used to drive tankers, container ships, 

cruise liners and power stations. 

Casting seems a very archaic process to the layman. 

It actually involves a very high level of precision 

work, calling for years of experience, an instinctive 

feel and team spirit, explains Jochen Wyrtki, 

who has managed the foundry at Augsburg for 

three years: “The big castings are worth as much 

as 130,000 euros, so nothing must wrong. In addition, 

it would take weeks until we’d be able to 

supply a replacement. With the high workload of 

our production plant, that would be a fiasco. This is 

why we check every machine and piece of equipment 

before each casting process. Casting not only 

involves the foundry men but also mechanics and 

electricians to make sure we are equipped to deal 

with any problems.” 

At the foundry things generally hot up above all at 

night. A total 20 MW of energy is available to the 

Augsburg works of MAN Diesel. The foundry needs 

up to 10 MW of electricity for melting the metal. 

The only solution here is to work at night, when the 

workload at the other parts of the plant are lower 

and the greatest reserves of energy are available. 

The smelting process for the biggest engine block 

takes about eleven hours. Initial preparations start 

at around 5 pm, while casting generally takes place 

in the small hours from four o’clock onwards. v 

© MAN Diesel SE 

Not just for MAN 

Besides crankcases, the foundry also produces cylinder 

heads, flywheels, supporting rings and crankshaft 

bearing caps for the company’s own diesel 

engines as well as components for turbochargers, 

which are also manufactured at Augsburg. But the 

firm also receives contracts from external customers. 

For example, the wind energy industry has rotor 

hubs and machine supports for wind turbines 

manufactured by MAN Diesel, while its affiliate 

RENK orders gearbox parts, and machine tool manufacturers 

buy machine beds made at Augsburg. For 

Jochen Wyrtki such external orders are important: 

“Job castings confront us with new technological 

challenges. If we only worked for MAN Diesel, the 

company could not develop further. This simultane- 

8 

ISSUE APRIL 2008

MAN DIESEL 

H 

ously allows us to check whether our prices are in 

line with the market. We must of course make sure 

that external orders do not deprive us of the capacity 

to cover our own requirements.” 

Unlike in the steel trade, the raw materials for the 

foundry are available in sufficient quantities on the 

international market. The company mainly uses 

pig iron and two different qualities of steel scrap 

which has been recycled. It procures pig iron from 

countries such as South Africa, South America and 

Canada. Its relationship with these suppliers is of 

key importance to ensure that the raw materials 

are of uniform quality. “We cannot use scrap from 

cars as this metal is too highly finished by the automotive 

industry. The various coatings are entirely 

unsuitable for casting. We mainly use waste produced 

during flame cutting and when dismantling 

steel structures, for example halls or rail track. The 

household appliance industry also provides very 

good raw materials in the shape of refrigerators, 

ovens and washing machines,” remarks Jochen 

Wyrtki. 

With a final shower of sparks the flow of metal 

slowly peters out from the ladles, with the last 

drops gleaming as they fall into the mould. Anton 

Schweyer and his team move back the containers to 

their original position. 17 days later they will know 

whether casting was successful. This is the time the 

crankcase has to remain in a pit to cool down before 

it can take centre stage in a new engine. 

Moulded by hand 

250 workers are employed at the foundry at Augsburg, 

and everyone of them is fired up about their 

profession. Many have been at MAN Diesel for over 

25 years and completed their apprenticeship at the 

company. “Most people think this is a bone-breaking 

business, something that’s not true at all. The 

heavy parts are always transported by crane, so that 

you don’t have to be a bodybuilder to work here. 

For me the particular fascination is having the result 

of your own work appear before your very eyes 

- in other words, the finished casting. The moulds 

for cast parts are made of plain pit sand, to which 

resin and hardener have been added. All moulds 

are handmade as MAN Diesel’s foundry is one of the 

five biggest handmoulding plants in Germany. The 

moulder generally makes his mould himself - years 

later he will still be able to say in which engine his 

casting was installed. 



9 

© MAN Diesel SE


MAN DIESEL 

For moving moments 

Line engineering for big marine diesel 

Ships‘ engines that are as tall as a house – true hightech 

equipment – it is here that HANSA-FLEX acts as 

a partner and OEM to MAN in the field of fluid line 

engineering. 

The two-stroke diesel engines, which operate at 

between 75 and 250 rpm, have an output of 97,000 

kW at the propeller and are used in big cargo ships. 

MAN Diesel‘s 4-stroke engines are manufactured as 

medium and high-speed engines. While 2-stroke 

engines are mainly used for merchant shipping, 

4-stroke engines are installed in passenger liners 

and special ships such as tugs or cable-laying ships. 

Fast little 4-stroke engines are also a popular choice 

for high-speed ferries. 

When it comes to developing new engines, Reinhard 

Thoms, the member of staff responsible for 

the design of hose lines for marine engines at MAN, 

can count on the advice and support of Michael Eggers 

from HANSA-FLEX‘s Hamburg branch. At this 

early design stage they work out what exactly is 

feasible to avoid subsequent cost traps and develop 

solutions which are up-to-date not only in terms of 

technology but also layout. Development times at 

MAN are greatly shortened by HANSA-FLEX‘s ability 

to promptly supply prototype samples for testing. 

Paying close attention to the manufacturer’s specifications 

and engineering drawings, HANSA-FLEX 

produces connecting elements ready for installation 

for the fluid technology of the marine engine. And 

not just for the lube oil and coolant pipes but also 

the air lines for the starting air, as well as the heavy 

oil and fuel oil, used to improve the flow characteristics 

of the heavy oil. PTFE hoses, which have been 

specially produced for this purpose by the PTFE 

hose experts at Boffzen, are used here as they are 

ideal for the reliable transport of hot fluids. 

© MAN Diesel SE © MAN Diesel SE 

All other hose lines and maritime industrial hoses 

are supplied to the engine manufacturer in Augsburg 

by HANSA-FLEX’s branches in Hamburg-Stellingen 

and Wilhelmsburg. These two sites on Ger- 

10 


ISSUE APRIL 2008

MAN DIESEL 

H 

many’s coast not only have the special equipment 

needed to deal with the large nominal widths stipulated, 

but are also specially certified by the ship 

classification company Germanischer Lloyd and 

other international classification organisations. 

And it is this very certification and supply from 

a single source that forms the basis for the cooperation 

between MAN Diesel and HANSA-FLEX. 

This allows MAN to minimise its procurement processes, 

with the engine manufacturer also enjoying 

clear cost advantages in terms of administration. 

The man responsible for coordination between 

the engine production plant in Augsburg and 

HANSA-FLEX’s works in Hamburg is Michael Eggers. 


MAN Diesel – leading provider 

of large marine diesel engines 

MAN Diesel is the world’s leading provider 

of large-bore diesel engines for 

marine and power plant applications. 

The company develops two-stroke and 

four-stroke engines, generating sets, turbochargers, 

CP propellers and complete 

propulsion packages that are manufactured 

both by MAN Diesel and its licensees. 

The engines have outputs ranging 

from 450 kW to 97,300 MW of power. 

MAN Diesel employs around 7000 staff, 

primarily in Germany, Denmark, France, 

the Czech Republic, India and China. 


HYDRAULIKPRESSE 11 

© MAN Diesel SE


CAMPINA 

But with cream please! 

Expert filling for a versatile range 

Three feed lines are required if chocolate pudding is 

to be swirled with vanilla pudding and then topped 

with cream. The heads of the filling machine accompany 

the containers on the conveyor belt and 

distribute the exact quantity of product required 

into each container via flexible PTFE corrugated 

hoses. In an unflagging one-second rhythm the 

hoses are moved along in step with the containers 

and then returned to their home position. One 

glance at the transparent hoses is all it takes for the 

plant foreman to tell whether it is cream, chocolate 

pudding, fruit yoghurt or vanilla sauce that is currently 

coursing through the pipes. This means he 

always has full control of the system to ensure a 

smooth product supply. One filling system can handle 

28,000 containers per hour, generally operating 

in a cycle of 36 hours. The machine is then cleaned 

automatically and switched over to a new product. 

Chocolate pudding topped with cream, red jelly with 

vanilla sauce, yoghurt with exotic fruit or milk pudding 

with a swirl of chocolate. Sweet desserts and 

speciality yoghurts from Campina are what foodies 

reach for throughout the day. A tasty snack, with hygienic 

packaging. 

Campina at Gütersloh produces a whole range of 

dairy products. The raw material here is milk. It can 

be processed as plain milk for drinking, mixed milk 

drinks, yoghurts and desserts as well as products 

made of cheese, butter and cream. The company 

regularly adds new specialities to its range: yoghurt 

with stracciatella, multi-flavoured “swirled” 

desserts, rice pudding with cherries with small 

portions in divided containers, which are filled 

separately. This international dairy producer never 

stops thinking up new ideas for the retail sector to 

make sure consumers are met with a wide selection 

of products in the chilled cabinet. 

This often involves quickly switching between 

products at the factory, something that is of course 

only possible with sophisticated process technology 

and high logistical efficiency. Tankers containing 

fresh milk for the dairy products constantly roll up 

at Gütersloh. Other deliveries include ingredients 

such as fruit pulp, processed fruit, chocolate chips, 

cream or sweet woodruff, as well as containers of all 

shapes and sizes, already equipped with labels for 

the different brands. There are of course also boxes, 

which are then put together as crates on pallets 

for shipment. Every day between 1,200 and 1,500 

pallets leave the factory laden with their delicious 

cargo, ready for distribution throughout Europe. 

Blended in the container 

Anyone walking through the production plant 

will be struck by the confusion of pipes containing 

brown, red or white liquids: chocolate pudding, 

fruit sauce or cream, which is conveyed via the filling 

system from the storage tanks to the containers 

standing ready. A sophisticated system of hose lines 

brings together the different ingredients in the filling 

machine and then blends them in the container. 

Line engineering plays a key role at the company. 

Things are of course rather tight at the filling machines. 

To fill a crate with twelve 500 gr containers 

for example, the feed lines for the ingredients 

have to be connected to the relevant filling heads. 

Special pipes were once used for this purpose. This 

resulted in awkward situations as they sometimes 

had to be bent into complicated shapes to fit into 

the confined space available. Great accuracy was 

required to compensate for the slight deformation 

involved. Fast and flexible changeover of the production 

machinery was difficult due to the timeconsuming 

process necessary here. 

The solution: PTFE 

Rainer Kahmann, the manager of the technical 

warehouse at Campina and Christian Koschorreck, 

responsible for engineering at Campina, consulted 

Mehmet Susever, MD of nautical elements. For 17 

years he has assisted Campina with process technology 

at the plant in the role of an external serviceprovider. 

All three started looking for alternative 

solutions and came across HANSA-FLEX Boffzen, 

the specialists for metal and PTFE hoses. Such hoses 

were absolutely ideal for Campina’s requirements. 

They joined forces to come up with the very best so- 

12 


ISSUE APRIL 2008

CAMPINA 

H 

lutions – so immediately presenting the specialists 

from Boffzen with an enormous challenge. 

“But HANSA-FLEX proved to be very patient and 

always responded quickly,” said Mehmet Susever, 

who is still delighted about their cooperation. “And 

even at the weekend we didn’t hesitate to commission 

HANSA-FLEX with the production of hoses. As 

the plant works non-stop, this meant we had to 

make use of the tight time slots available when 

the machines were being cleaned and prepared 

for new campaigns.” The specialists in Boffzen have 

proved themselves to be committed partners to 

Campina, something that has remained unchanged 

today. “HANSA-FLEX is always at the end of the supply 

chain in terms of process technology - in other 

words, we can only determine the exact measurements 

for the PTFE hoses once a process line has 

been converted,” remarked Mehmet Susever. “But 

very fast delivery is then required. We order the 

hoses by phone, and they’re available just a few 

hours later.” 

One by one the connecting pipes to the filling heads 

have now been replaced by transparent PTFE corrugated 

hoses, which are ideal for areas with high 

hygiene requirements. They have the advantage 

of being not only temperature-resistant but also 

odourless and tasteless - in other words, safe for 

use with foods. Compared with conventional industrial 

hoses, they greatly improve product quality, 

are easy to maintain and provide for CIP (cleaningin-place) 

processes. In addition, PTFE hoses do not 

include metal parts. This is important for product 

safety: no metal particles can get into the containers. 

One special advantage of PTFE hoses is of course 

their flexibility, which caters for minor variations in 

dimensions. They offer the necessary flexibility so 

that at filling plants, the feed lines can be quickly 

connected to the filling heads. Campina can thus 

achieve a significant reduction in set-up times and 

process costs. 

At a plant that continuously manufactures fresh 

dairy products unscheduled downtimes should 

never last very long. This is why Rainer Kahmann, 

as the manager of the technical warehouse, has 

localised all key spare parts and keeps sufficient 

stocks of these components. Including of course a 

small supply of PTFE hose lines, articles which really 

only become unusable due to improper handling or 

mechanical influences. To avoid such influences 

Campina also uses PTFE hoses in areas where filling 

does not take place. These hoses feature a metal 

braid jacket or are protected from abrasion through 

contact with the ground by double metal spirals 


HYDRAULIKPRESSE 13


BRANCHES 

v 

HANSA-FLEX Thailand 

Sights set on expansion 

HANSA-FLEX Hydraulic Thailand can trace its 

origins back to 2003, when the beginnings of a 

small-scale business relationship were marked by a 

visit to the HANSA-FLEX head office in Bremen and to 

HANSA-FLEX Metal Hoses in Boffzen by Kitisak Suwanwong, 

Amporn Khanarsa and Yanyong Homsrivaranon. 

That visit developed into a partnership 

which still endures today, and which led in mid 2006 

to the establishment of a branch office in Bangkok, 

the political, economic and cultural center of the 

country. 

At the time, HANSA-FLEX was suddenly attempting 

to establish itself as a new brand name on a 

hydraulics market which was already able to offer 

a wide variety of products from all over the world 

at any time, with competitors who had been operating 

in the sector for 30 years. Nevertheless, the 

Thai managers invested all their efforts in ensuring 

that the HANSA-FLEX name quickly became known 

among the customer base. 

The reasons their efforts were so successful lay 

primarily in the high-quality, in-demand products 

the company offered and in an extraordinarily 

high level of service. That standard of service was 

experienced at first hand by Enrico Kieschnick from 

the Bremen head office on a recent visit. “The local 

colleagues are highly committed, and they have 

plenty of plans for the future,” he reported. 

Nowadays HANSA-FLEX Thailand operates two 

branches in Bangkok, with its population of 11.5 

million people, and one other in Saraburi province. 

The company is now not only able to supply its customers 

with the complete range of hydraulic hoses, 

metal and PTFE hoses and corrugated hoses, it also 

fabricates pipelines, special pipes and fittings. The 

fittings are designed to customer specification, so 

they can be fitted in any application and in any position. 

The special pipes and fittings manufacturing 

facility is located at the second Bangkok branch in 

Chaokhuntaharn. With a team of in-house engineers, 

HANSA-FLEX Thailand provides customers 

with an on-site installation service. Kitisak Suwanwong 

and his staffs receive intensive support and 

assistance in their work from the Bremen head office 

and from the metal hose specialists in Boffzen. 

Frank Schmidt, export manager of HANSA-FLEX 

GmbH, and his team are particularly focussed on 

supporting and encouraging their colleagues in 

Thailand wherever and whenever possible. 

Customers and plans 

One of HANSA-FLEX Thailand’s key customer accounts 

is the Siam Cement Group, the largest 

industrial conglomerate in the country with over 

100 separate business units operating in industries 

including chemicals, paper and construction materials, 

as well as cement of course. The company’s 

mighty excavators and concrete mixers are fitted 

with hydraulic hoses from HANSA-FLEX Thailand. 

The service package also includes on-site fitting 

to vehicles and equipment by HANSA-FLEX technicians. 

The local managers in Thailand are considering 

introducing FLEXXPRESS to handle these service 

operations. Other key accounts include transformer 

manufacturers and the Bangkok Metro transport 

company, as well as numerous industrial concerns 

from the region. Since mid 2006 the sales of 

HANSA-FLEX Thailand have been steadily rising. The 

potential is certainly high, since industry accounts 

for some 45 percent of the country’s gross domestic 

product. 

The figures speak for themselves. In 2007, metal 

hoses and special pipes accounted for 75 percent 

of HANSA-FLEX Thailand’s total sales; 18 percent 

were hydraulic hoses; and seven percent were other 

components. Expansion is very much on the cards in 

future. In order to achieve long-term success, local 

managers Kitisak Suwanwong and his colleagues 

are looking to adopt the highly promising network 

system and, backed by HANSA-FLEX head office, to 

offer their customers a level of service which will 

establish the HANSA-FLEX name firmly on the Thai 

hydraulics market. 

14 

ISSUE APRIL 2008

BRANCHES 

H 

Augsburg branch: the concept artists 

Quick start with OilQuick 

The close interlinking of all HANSA-FLEX branches 

and the use of X-CODE also played a role in the decision 

in favour of HANSA-FLEX. As all hose connectors 

are supplied with X-CODE as standard, replacement 

hoses can easily be obtained from the nearest 

HANSA-FLEX branch. On building sites, FLEXXPRESS 

also provides on-site assistance. Hence the cooperation 

between OilQuick and the colleagues in 

Augsburg has a beneficial effect on all branches in 

the region of the Federal Republic of Germany. In 

addition, the OilQuick fitters can turn to the nearest 

HANSA-FLEX branch if they urgently require components 

when fitting a quick-change system for 

their customer. They can easily obtain all replacement 

components on a delivery note, as in an outline 

agreement, OilQuick has negotiated conditions 

with HANSA-FLEX, which are valid in all branches. 

OilQuick therefore minimises the effort for procurement 

and has a guarantee that the quality of the 

components remains the same. 

Herbert Wintersteiger (FLEXXPRESS), Wolfgang Raunft (workshop/stock), Thomas Karg (branch manager), 

Horst Heinrich (workshop/stock) 

With the recently opened branch in Augsburg, 

HANSA- FLEX has increased the density of its service 

network in one of the most important economic regions 

in Bavaria. Everything began with a quick start. 

Although the branch only opened in November 2007, 

branch manager Thomas Karg, who has 15 years of 

experience in hydraulics, developed a concept for the 

cooperation with OilQuick Deutschland GmbH. The 

result is a classic example of cross-sector cooperation 

between HANSA-FLEX and its customers. 

OilQuick manufactures and distributes quickchange 

systems for attachments to building machinery. 

Within seconds the machine operator can 

exchange the tools on his excavator, wheel loader, 

or fork-lift truck, regardless of their size or make, 

without leaving the driving seat. The system automatically 

connects all the hydraulic hoses of the 

attachments. This saves time, and as is well known, 

time is money. 

As OilQuick supplies quick-change systems for all 

leading makes of hydraulic machinery throughout 

the world, Franz Schauer, the manager of the 

German OilQuick agency decided on a cooperation 

with HANSA-FLEX. At a stroke, the company 

therefore ensured the support and expertise of the 

HANSA-FLEX Group for the continuously increasing 

network of branches and mobile workshops. This 

is a service, which no other hydraulic supplier can 

provide. 

OilQuick is using this advantage to extend and 

reinforce its market position. The OilQuick design 

department adapts its quick-change system to any 

of the customer’s machinery. The hydraulics service 

provider supplies complete sets of hoses designed 

by OilQuick for the many different makes of machinery. 

Where necessary, the OilQuick fitters employ 

FLEXXPRESS vehicles for the assembly of the sets 

on site with the final customer. The advantage of 

this close cooperation: FLEXXPRESS is fully included 

in the manufacturer’s assembly requirements. With 

this, OilQuick increases its performance, and keeps 

its own capacities flexible. 

After just six months, the Augsburg team can therefore 

state: “We are already an accepted partner in 

the Augsburg region.” This is a great incentive for 

the current development of close cooperation with 

other customers. 

Close cooperation strengthens 

the market position 


HYDRAULIKPRESSE 15


BVV – BOCHUMER VEREIN VERKEHRSTECHNIK 

Precision wheels from the coalfields 

Baptism of fire 

Keeping things rolling 

Various production systems were not routinely 

overhauled until the end of the year. Entire production 

units underwent a thorough overhaul. This 

extensive work calls for careful planning every time 

- after all, the manufacturing equipment needs to 

go back into production on schedule without any 

delay. 

High-speed trains race along the track at 250 km an 

hour. This puts wheels under enormous strain, calling 

for maximum reliability. The precision wheels manufactured 

by Bochumer Verein Verkehrstechnik (BVV) 

for the German and international railway companies 

are designed to provide top levels of accuracy and reliability. 

This means they are correspondingly dear to 

manufacture. 

In the historic-looking factory buildings based in 

the heart of the coalmining town of Bochum 580 

employees use high-tech machinery to produce 

some 120,000 locomotive wheels in various configurations, 

operating round the clock, seven days 

a week. This medium-sized company belonging to 

the Georgsmarienhütte Group of Companies has 

operated in the steel casting sector since 1841. 

Such precision wheels literally go through a baptism 

of fire as the special steel, which is alloyed to cope 

with the stresses imposed on locomotive wheels, is 

heated to a temperature of around 1300 degrees C. 

The red-hot block of steel is forged into shape using 

a special press with a force of 6,000 t. 

Locomotive wheels are made of a single piece of 

metal for safety reasons as weld seams are unable 

to meet the necessary standards. The red-hot blank 

for the wheel, which has been previously sawn into 

shape, is processed using a forging press and then 

calibrated in subsequent work steps on a 2,000 

t press. Next the outer contours of the wheel are 

checked by measurement with a laser. 

Next comes fine machining, a challenging task that 

is performed by robots and high-performance precision 

machines at CNC machining centres. At the 

end of the production process are wheels which will 

run 100% true, down to a hundredth of a millimetre, 

and are designed to ensure reliable operation in 

heavy-duty rail traffic whatever the weather. 

In the planning phase the Repairs, Maintenance 

and Service department first of all works out the 

level of reconditioning and/or replacement work 

required for each machine. This phase also identifies 

any leakage. The behaviour of the machines during 

production provides pointers about measures that 

might be necessary. Such information allows the 

company to draw up exact plans for the overhaul 

and order all spare parts needed in good time. Surprises 

may however still be in store. When panelling 

is removed from the machinery, this may reveal 

damage and defects that were previously hidden, 

such as a leaking hydraulic cylinder or even a unit 

with reduced capacity levels. If this is the case, specialists 

and technicians from external companies 

will have to be called in to help the maintenance 

team with the overhaul. The only thing that is certain 

in this process is the end date for the service: 

that’s definite! 

To make sure its machinery and systems are always 

ready for operation, BVV involves the service staff 

of the machine manufacturers not only in the overhaul 

but also in the servicing process. They are of 

course familiar with all technical issues relating to 

their machines. Here HANSA-FLEX’s Bochum branch 

acts as the specialist for hydraulic hose lines and 

repair of the line engineering as a high level of hydraulics 

is involved in the forging and rolling mills. 

HANSA-FLEX is also increasingly accepting work 

from plant manufacturers when it is a question of 

line engineering and services. All services involving 

hydraulics are coordinated by Christoph Bergfried 

from the Bochum branch - and not just when overhauling 

is underway. 

16 


ISSUE APRIL 2008

BVV – BOCHUMER VEREIN VERKEHRSTECHNIK 

H 

Regularly every Friday 

When it comes to routine production, the company 

relies on HANSA-FLEX as a system partner. 

FLEXXPRESS is contracted to maintain the hydraulic 

components of its machinery. Every Friday two 

mobile workshops turn up with an comprehensive 

stock of spare parts. The crews inspect the hydraulic 

systems and carry out urgent repairs to the hose 

lines in agreement with the foremen of the individual 

plant sections. 

All work is carefully documented as BVV is subject 

to especially stringent certification as a supplier to 

the rail sector. The production systems always have 

to be kept in perfect condition as wheels are safetyrelevant 

precision components. It must be possible 

to reproduce their specified quality standard at any 

time. 

X-CODEplus ensures transparency 

It goes without saying that BVV has opted for 

X-CODEplus. As soon as a hose line is replaced, 

it is marked with X-CODEplus. Records kept by 

HANSA-FLEX state when each hose line was installed 

and why it was replaced: whether it had 

to be exchanged due to wear or in the course of 

general preventative maintenance. This ensures full 

transparency at all times. Weak points are detected 

and systematically eliminated. The records for the 

hose lines identified with X-CODE can be viewed 

at HANSA-FLEX via the Internet. Stoppages are recorded 

there, and this information can be used to 

take measures to avoid unplanned downtimes. By 

opting for HANSA-FLEX, a company can increase 

the reliability and safety of its machinery, optimise 

availability and minimise unscheduled shutdowns. 

BVV has opted for system 

partnership with HANSA-FLEX. 

Because … 

… we appreciate the professional expertise 

of its staff and the personal support 

offered by the FLEXXPRESS service technicians. 

And of course the fast delivery 

capability of the Bochum branch. 

We can drastically reduce our stocks of 

hydraulic hose lines, so minimising the 

costs of storage and maintenance of 

spare parts. And: New hydraulic hose 

lines from HANSA-FLEX always have the 

full service life of six or so years, comments 

Rolf Grandt, head of the Repairs, 

Maintenance and Service department, 

something that is an advantage in terms 

of insurance. 


HYDRAULIKPRESSE 17


OIL SERVICE FOR THE EMS BARRIER 

Everything shipshape for the magnificent „AIDAbella“ 

Preventative maintenance on the gateway to the North Sea 

Papenburg since 1795 and now boasts the world’s 

most modern shipbuilding facilities. Virtually the 

entire manufacturing process has been digitised. 

Using the so-called “Lego building block principle” 

the shipyard not only produces cruise liners but 

also special ships such as gas tankers, ships for the 

transport of livestock and ferryboats. 

The 250 metre or so long Aida Clubschiff carefully 

inches its way through the Ems flood barrier. For 

the cruise liner built at the Meyer Werft shipyard in 

Papenburg, the Ems barrier is the final hurdle before 

passing into the open waters of the North Sea. 

The Ems barrier at Gandersum is one of the most 

modern of its type in Europe and has been in operation 

since September 2002. This structure, 476 

metres in length, is operated by the Aurich branch 

of the Lower Saxony Water Management, Coastal 

Defence and Nature Conservation Agency (NLWKN). 

Its key function is to protect the German coastline, 

in particular from storm surges. If waters rise over 

3.70 m above mean sea level (amsl), the gates of 

the flood barrier will close off the hinterland, as 

happened recently during the autumn storms last 

November. 

Construction of the storm surge barrier has done 

away with the need for continuous adjustment of 

the main dykes upstream along the Ems (towards 

Papenburg) and its tributaries, something that 

would be required every 30 or 40 years according 

to experience. 

The barrage function of this structure also contributes 

to the economic performance of the entire 

region by ensuring that the shipping channel 

between Papenburg and Emden remains more or 

less passable and permits the passage of ships built 

at Papenburg’s Meyer Werft on the Ems with a top 

water level of 2.70 metres amsl. The shipyard – one 

of the biggest employers in the Emsland district 

– has an outstanding international reputation for 

building upmarket cruisers, with the largest measuring 

up to 38 m in width and 300 m in length. 

This traditional firm has been constructing ships at 

To enable passage of such enormous ocean liners 

from Meyer Werft to the open sea, the water 

level of the Ems can be raised up to 2.70 metres 

amsl. There should be no hitches in this process, 

with three such occasions being planned for 2008: 

everything is planned down to the finest detail. 

Whenever a ship is due to pass through, the flood 

barrier has to dam up the Ems to provide the agreed 

depth of water on the date agreed. Water has to be 

pumped behind the floor barrier depending on the 

ship’s draught and the tide level of the Ems. This 

task is performed by gigantic pumps with a total 

power of 6,300 kW. The combined delivery rate of 

the six pumps is some 100 cubic metres per second, 

including with fluctuating tide water levels. Water 

is taken in via the pump inlet located in the part of 

the barrier facing the sea and closed off with steel 

flood gates when the pumps are not in operation. 

The pumps are installed in six piers, with water 

flowing from two sides. They are driven with a 

power output of 6,300 kW, forcing water into the 

Ems out of pumping channels up to four metres in 

width and 2.60 metres in height. The inlet cone, 

the suction cone and above all the pump spiral 

installed in the piers are prefabricated parts made 

of high-grade concrete. The diameter of the impellers 

range between 2.25 and 2.6 m. If one of these 

pumps breaks down, the decisive inch of water may 

be lacking that allows a ship to pass into the open 

sea in the scheduled time slot. 

A timely oil check 

NLWKN therefore performs preventive maintenance 

to ensure the availability of the pumps in 

the flood barrier as any malfunction soon upsets 

the programme for the passage of a ship along the 

Ems. When Uwe Narten, the operations engineer 

18 


ISSUE APRIL 2008

OIL SERVICE FOR THE EMS BARRIER 

H 

responsible for smooth functioning of the barrier 

pumps, recently noticed foam in the inspection 

glass for the gear oil, he investigated the matter immediately. 

The appearance of foam during operation 

causes problems with the oil lubricating film, 

resulting in increased wear, metal erosion and in 

the worst-case scenario, to complete failure of the 

pump gear. 

As a precautionary measure HANSA-FLEX’s Oil Service 

was consulted to obtain a clear picture about the 

condition of the pumps. Samples were quickly taken 

and immediately analysed at Wearcheck. Analysis 

showed that the tanks contained two different 

types of oil whose additives were not compatible 

and were therefore producing the foam. Slight 

metal abrasion was also observed, originating from 

the gearwheels and bearings. It was therefore advisable 

to optimise the oil status as a preventative 

measure. 

Oil change from a single source 

Uwe Narten was responsible for coordinating the 

complete oil change planned for the installation 

with HANSA-FLEX’s local branch in Emden. The contract 

was performed by FLEXXPRESS with the service 

technician Volker Brodowski. For a week he had 

his hands full with all the work on the 400 m long 

flood barrier. As agreed in the contract, HANSA-FLEX 

had made careful preparations, organising pumps 

and filters and also dealing with proper disposal of 

the waste oil. In all, 1,500 litres of contaminated 

gear oil was pumped out and stored in the containers 

standing by. The next step was to flush through 

the system with new oil. Here Volker Brodowski’s 

brief was to achieve a residual oil level below two 

percent and to reliably filter out the abraded metal 

particles from the entire installation. Proper disposal 

was also ensured for the flushing oil. Only 

then was the clean gear oil pumped in, using filters 

with an absolute fineness of 3 µ to prevent any new 

contamination getting into the system. 

Following thorough inspection and the trial run 

Uwe Narten now sums up the operation as follows: 

“This preventive oil change means that we are well 

equipped to deal future tasks - the efficiency of the 

installation is assured”. At the end of the interview 

he also tells us that passage of the “AIDAbella” will 

be possible at the end of March without the help of 

the water drawing pumps: there will probably be 

enough water in the Ems. 


HYDRAULIKPRESSE 19 

© Meyer Werft GmbH


TRAINING CENTRE 

The new way 

Further training as hydraulics specialist (HWK) 

Wherever one looks in industry today, almost no machines 

function without hydraulics. Cranes do not lift, 

excavators do not dig, grabbers do not grip, robots 

do not assemble and trains do not run without the 

aid of hydraulics. It is therefore very surprising that 

there is no state-recognised skilled trade of „hydraulic 

specialist“, because there is a demand for such specialists. 

HANSA-FLEX has now taken the initiative, in 

order to put further training as a hydraulic specialist 

on a broader basis. 

In order to secure the future demand for specialists 

in technical fields, in cooperation with the Chamber 

of Trade of Lower Bavaria/Upper Palatinate, 

HANSA-FLEX has developed a further training 

concept which concludes with an examination as 

a hydraulic specialist by the Chamber of Trade. This 

is an opportunity which has been rather neglected 

by chambers of trade over the past years, although 

it has been included in the training statutes since 

1990. The further training is an incentive for good 

technicians, for whom up to now there has been no 

career path as a skilled tradesman. However, it is 

also intended for staff from commercial fields, who 

can be employed more flexibly thanks this training, 

and for whom new career prospects are opened up 

because of their technical know-how. 

The first cohort completed its further training as 

officially recognised hydraulic specialists with an 

examination by the Chamber of Trade in Regensburg 

in 2008. The five participants all passed both 

the written and the practical examinations with the 

grade “good”. Previously, they had all completed 

their commercial training with HANSA-FLEX – a 

prerequisite for participation. 

The next ones please ... 

The next course for hydraulic specialists (HWK) begins 

in September 2008. An evaluation workshop 

after the first course led to the decision: “We shall 

continue, because the growth of the HANSA-FLEX 

Group demands a directed development of staff.” 

Hydraulic specialist not only help to cover the demand 

in technical fields, but also underline HANSA- 

FLEX’s ambition to appear as a system provider. 

The training concept has been optimised from the 

experiences of the first course. The HANSA-FLEX 

personnel development department has specifically 

prepared and supervised this process. The optimised 

further training now includes a 10-week theoretical 

and practical training at the HANSA-FLEX training 

centre in Dresden-Weixdorf and integrated on-thejob 

training with neighbouring specialist companies 

in Königshofen which manufacture hydraulic 

components, or are involved in engineering and 

machine construction, special pipes and fittings 

and cylinder repairs. For individual special subject 

such as electro-hydraulics, lecturers from cooperation 

partners are employed - in this case from the 

Society for Vocational Training and Further Training 

in Hoyerswerda. 

On the practical test-beds in Dresden the course 

participants deepen their theoretical training with 

practical simulations and exercises. During their 

training in the fundamentals of hydraulics, the participants 

learn to design pressure reservoirs, gain 

an introduction to proportional hydraulics, become 

familiar with axial piston pumps and their regulators, 

and produce circuits according to technical 

aspects. The budding hydraulic specialists are also 

trained in the design of hydraulic systems and learn 

how pipe and hose circuits are dimensioned and 

manufactured. 

The further training concept also includes technical 

fields, which although they are not relevant 

to the examination, are essential for HANSA-FLEX 

employees, for example pipework technology. Ul- 

Training seminar schedule April – May 

07.04. Grundlagen der Dichtungstechnik Eisenberg 

10.04. Grundlagen der Leitungstechnik Bremen 

14.04. – 18.04. Grundlagen der Fluidtechnik Teil 2 Dresden-Weixdorf 

22.04. – 23.04. Befähigte Person Leitungstechnik Bremen 





For further information please contact Mrs. Anne Schmidt (training centre Dresden-Weixdorf/Germany): +49 - 351 - 413 97 19 

in German only 

20 

ISSUE APRIL 2008

TRAINING CENTRE 

H 

IHA expands further training 

Foundation stone for a milestone 

timately the further training course should secure 

HANSA-FLEX’s requirements for specialists and 

offer additional vocational prospects to good employees. 

The prerequisites for participation in a course as a 

hydraulic specialist are firstly a completed vocational 

training, and of course very good technical 

understanding, great willingness to learn, and 

also self-motivation. For HANSA-FLEX employees, 

release by the particular regional manager is also 

necessary. Those who complete the course will all 

be taken on by HANSA-FLEX - they know the company 

philosophy and after concluding their training 

can be employed flexibly. Employees with a Chamber 

of Trade Certificate have not only been taught 

the theoretical basis of hydraulics, but have also 

had experience in the training workshop and in the 

associated specialist companies. They are in a position 

to answer customers’ enquires about hydraulic 

components, to design simple hydraulic systems 

and hydraulic cylinders, and to produce pipework 

according to customers’ requirements. In addition, 

they also gain an insight into cylinder repair 

and the manufacture of seals and special fittings. 

In future it is planned to open the further training 

as a hydraulic specialist to external participants. Interested 

customers should contact the HANSA-FLEX 

training centre (+49 (0)351-4139719, a.schmidt@ 

hansa-flex.com). 

On 18 April 2008 the foundation stone for the International 

Hydraulics Academy (IHA) will be laid in 

Dresden-Weixdorf. The HANSA-FLEX Group is participating 

in this academy and making its valuable 

knowledge from all fields of fluid technology available. 

IHA is a reaction to the rapidly growing demand 

for courses. The ambitious International Hydraulics 

Academy is a milestone in the field of internal and 

external training and further training, as it considerably 

expands the previous training and further 

training facilities of the HANSA-FLEX Training Centre. 

Through this transfer of know-how, employees 

and customers of the hydraulics service provider can 

profit from its long years of experience in courses 

and training schemes. Additional seminar modules 

and an extended staff of trainers, together with the 

cooperation with the Technical University and the 

College of Further Education in Dresden, enable 

all fields of fluid technology to be included in the 

course. Additional testing and research capacities 

are based on the latest technologies. 


21


IN CONVERSATION 

Joachim Foltan: 

“Ultimately it is a focus on service and sympathy that count” 

At the age of 37 years Joachim Foltan is the youngest 

regional manager at HANSA-FLEX. After reorganisation 

of HANSA-FLEX’s Solingen Region, he took over 

the operations at Wittlich, Saarlouis, Oberhonnefeld, 

Idar-Oberstein, Konz (incl. series production) and 

Koblenz. In 2007 the Friedrichsthal-Maybach branch 

became the newest member of this region. 

Mr Foltan, who started off his career as a commercial 

trainee, first came into contact with hydraulics 

at a young age. In the holidays he worked for a 

construction machinery firm and was responsible 

for manufacturing hydraulic hoses when spare 

parts were needed. When Joachim Foltan joined 

HANSA-FLEX, he already had a clear idea of his 

future. He started work in the Sales department 

on 1 July 1996. The first task for the man from 

Wittlich was to develop a clientele in the region 

south of Trier, the Saarland and adjacent parts of 

the Palatinate and to identify the best site for a 

new branch: Nine months later saw the founding 

of the Saarlouis branch, making Joachim Foltan 

the youngest branch manager in the organisation. 

Joachim Foltan spoke to HYDRAULIKPRESSE about 

his enthusiasm for hydraulics and how this has lead 

to a fascination with HANSA-FLEX. 

HYDRAULIKPRESSE: How did it come about 

that you opted for hydraulics at such an early age? 

Joachim Foltan: I was happy working on the commercial 

side of industry and was also successful. 

But I was fascinated by hydraulics as well, a subject 

that would not let me go. There is hardly any machine 

that is not equipped with a hydraulic system. 

Whether we are talking about the biggest oil rigs 

in the world, gigantic mining excavators, container 

ships or operating tables in hospitals, hydraulic systems 

make work easier – often without us even noticing. 

I have seen hydraulics at work 1,800 metres 

down at a coal mine in the Saarland and in a wind 

turbine 140 metres up in the air. Fantastic. 

HYDRAULIKPRESSE: Your enthusiasm for 

hydraulics soon gave rise to a fascination with 

HANSA-FLEX. 

Joachim Foltan: I quickly realised that 

HANSA-FLEX is an expanding company that offers 

young people every opportunity to take on 

responsibility. This meant that during my time at 

Saarlouis I was soon able to make the branch a respected 

partner in the region as well as a successful 

HANSA-FLEX operation. In addition, HANSA-FLEX 

is an innovative company which gives its own impetus 

to hydraulics and acts as a trendsetter in this 

sector. Here I only need mention X-CODE, which has 

revolutionised the procurement of spare parts. 

HYDRAULIKPRESSE: In Saarlouis you put 

together a strong team, which has even formed 

the basis for another branch in Konz. Under your 

management the Saarlouis branch personally carried 

out an audit as a supplier to the German Armed 

Forces in 2005 and passed with flying colours. How 

do you manage to pass on your enthusiasm to other 

people? 

Joachim Foltan: I simply try to communicate 

my enjoyment in providing attentive and obliging 

customer service to all staff. It’s like this: All our 

branches are staffed by committed, well-qualified 

people, who mainly have trained as technicians or 

workmen. They can work wonders when it’s a question 

of technology! But the way in which we stand 

out from the competition often lies in the quality 

of service. In other words, issues such as “What approach 

should I use with customers?”, “How can I 

ensure they are happy dealing with our company” 

or “How can I solve their problems?”. I would like to 

pick up on this, for ultimately it is a focus on service 

and sympathy that count with customers. 

I myself love selling and always tell my staff: If you 

can sell yourselves, the rest will follow of its own 

accord. Acting naturally, not putting on a front - 

customers notice whether our friendly approach 

and manner are genuine or not. With our hydraulics 

system partner concept we have fulfilled all conditions 

for continued success. But every day we need 

to ask ourselves whether we are friendly and attentive 

towards customers, and of course competent 

as well. 

HYDRAULIKPRESSE: 

In other words, repeatedly 

questioning one’s own success? 

Joachim Foltan: That’s important. Although 

HANSA-FLEX is enjoying continuous growth, we 

shouldn’t become complacent. This is why I regularly 

agree targets with the field team and other 

staff at executive level in order to focus customers’ 

attention on certain products for a while, for 

example on sealing technology or currently, the 

new programmes for moulded or industrial hoses. 

I expect an open approach from everyone to make 

sure we can tap into new fields of business. For 

example, we recently came up with an innovative 

solution for an important customer, who until then 

had used costly curved stainless steel pipes for his 

line engineering, allowing this component to be re- 

22 


ISSUE APRIL 2008

IN CONVERSATION 

H 

placed by moulded hoses. This offers the customer 

greater flexibility during installation and helps him 

avoid the increases in the price of stainless steel. 

HYDRAULIKPRESSE: But what about the 

motto “never change a running system”? 

Joachim Foltan: That’s not my philosophy. If you 

always do the same thing, nothing new will ever 

result. You won’t notice the changes in the market, 

you’ll miss new better solutions. I aim to put 

processes in a new light from time to time – and to 

change them as well. For as the proverb runs, “Better 

is the enemy of good”. I want to avoid complacency 

and mindless repetition on the part of staff. 

When I took over the region, I also put three 

FLEXXPRESS vehicles into service. After just a year it 

could be seen that customers had been waiting for 

this mobile service. Another three vehicles are due 

to be added in 2008. 

HYDRAULIKPRESSE: Are you setting the 

course for the future? 

Joachim Foltan: Besides my role as a regional 

manager, I am also establishing a foreign business 

in Luxemburg as its MD. Luxemburg has always 

been a gap in our branch network: until now our 

customers there have been managed from Germany. 

Luxemburg has big industrial companies, which 

are key accounts for HANSA-FLEX and like buying 

in their own country. They are eagerly awaiting 

our branch in Luxemburg, which is due to open in 

June. 

HYDRAULIKPRESSE: Given your level of 

engagement, we have to ask how you manage all 

this? 

Joachim Foltan:HANSA-FLEX is a great company to 

work for. I love my job and still look after important 

customers myself. In my case work and spare time 

often blur into one. This would undoubtedly not be 

possible without my wife Silke. She puts things into 

perspective and helps me to cope at times when I’m 

under a lot of stress. She assists me in every possible 

way, provides excellent advice and pinpoints 

the key issues. By the way, we have both booked an 

XWORLD trip. On stage 40 of the tour we will be setting 

off for exciting destinations from St Petersburg 

in Russia. Via the North Cape we will then head for 

Scandinavia, a region of the world that my wife is 

mad about. 

HYDRAULIKPRESSE: 

When it comes to 

heading for set goals, the responsibilities involved 

in the system provider concept also increase the 

demands on staff at HANSA-FLEX. 

Joachim Foltan: Here HANSA-FLEX has responded 

by offering to train staff to qualify as a Hydraulics 

Technician (Chamber of Trade). The idea is to show 

all employees that if they are committed, they 

will be supported by HANSA-FLEX to take on new 

responsibilities every step of the way. If for example 

an employee who has been at the workshop 

for years feels the urge to try his hand in sales, he 

can apply to me. We’ll get together and work out 

how he can take on new duties. I have realised one 

thing: staff at HANSA-FLEX like being given new 

responsibilities. And this is part of the fascination 

exerted by HANSA-FLEX. 


HYDRAULIKPRESSE 23


EMPLOYERS’ LIABILITY INSURANCE ASSOCIATION 

The new BGR 237 is on its way 

Focus on practice 

But what is new about BGR 237? 

Ulrich Hielscher provides us with a brief summary: 

“First of all, it goes into great detail. It tells users 

of hydraulic hose lines and pipes how they can prevent 

damage from occurring in the first place. The 

scope of testing and relevant criteria are explained, 

and advice on installation and tips from practically 

minded experts is also provided. The entire text is 

illustrated with plenty of pictures and diagrams. 

For example, the new regulation describes circumstances 

resulting in failure such as tensile and 

compressive loads, temperature influences and the 

effect of vibrations. Information about safe replacement 

and troublefree fitting of hydraulic hose lines 

is not lacking either. This also includes tips on how 

to select and order such lines.” 

Painted hose lines 

Below maximum bending radius 

HANSA-FLEX training manager 

Ulrich Hielscher 

For many years HANSA-FLEX has been involved in 

advisory boards, specialist committees and working 

groups at the employers‘ liability insurance association, 

contributing up-to-date specialist knowledge 

about hydraulics for the formulation of new standards. 

In summer 2008 BGR 237, the new regulation 

from the employers‘ liability insurance association 

which lays down rules for the safe usage of hydraulic 

hose lines, is due to come into force. HANSA-FLEX 

training manager Ulrich Hielscher has been involved 

in this process in an advisory capacity. 

This new regulation will supersede the current 

provisions of ZH 1/74 (1988), which also contains 

safety rules for hydraulic hose lines, and will provide 

operators of hydraulic systems with a practical 

guide for the proper handling of hydraulic hose 

lines. Today hydraulic lines have to cope with everincreasing 

operating pressures, shorter cycle times 

and extended machine running periods. This results 

in major physical stresses. And this is why the new 

considerably more detailed safety regulation has 

become necessary. 

This makes visual inspection of a hose line by 

the operator easier: according to BGR 237 he 

has to check whatever he can see. But how often 

should such inspections take place? 

“Well, the operator has to perform his own risk assessment 

on his equipment: it is up to him to decide 

when to inspect his hose lines. The recommendations 

according to the requirements talk about 

every twelve or six months, whereby the specifications 

of the machine manufacturer should always 

be taken into account as well. The legal basis for the 

obligation of inspection can be found in the German 

industrial safety regulations, which finalise the 

stipulations of the German health and safety law.” 

This however also means that any extension 

in inspection periods must be tenable and 

justified in terms of technical safety. But why 

is it even necessary to make regular checks of 

hydraulic hoses? 

“Major stresses, whether they are mechanical, thermal 

or chemical in nature, bring about leakage or 

heavy losses of oil or may even cause hose lines to 

burst, resulting in machine failures and production 

stoppages. Not to mention possible harm to man 

and the environment from escaping oil, fires if such 

oil catches light in contact with hot machine parts 

or ripped hose lines whipping about.” 

Rough negligence 

Kinked hose line 

24 


ISSUE APRIL 2008

EMPLOYERS’ LIABILITY INSURANCE ASSOCIATION 

H 

Operator’s obligations 

At the end of the day, the responsibility for compliance 

with the safety regulations thus lies with the 

manufacturer - but also with the operators of machinery 

and systems. It is their obligation to ensure 

maximum safety by handling hydraulic hose lines 

according to the requirements. “This obligation is 

enshrined in the statutory provisions, norms and 

the regulations of the employers’ liability insurance 

association. This starts with the new machinery 

directive 2006/42/EC, which specifically deals with 

hydraulic hose lines and connection technology, 

and is resumed in the international DIN EN 982 

standard listing the safety requirements for fluid 

power systems.” 

But many operators do not know that ignorance is 

no defence - and will not save them from punishment. 

This was one of the reasons prompting the 

employers’ liability insurance association to introduce 

the new BGR 237 safety regulation. Plant operators 

are now informed how to deal with safetyrelevant 

hydraulic components. Another reason is 

that every industrial accident is one too many. 

But how can operators spot defects? How can 

they see that breakdowns are inevitable? 

“For example, from hose lines that are kinked, 

brittle or painted, welded fittings, lines that have 

been installed so they are too short or are subject 

to torsion and abrasion. Another pointer is when 

the minimum permissible bending radius is not observed. 

What is needed here is proper installation 

that takes account of all technical aspects of hose 

mechanics. In other words, observe the minimum 

bending radius, install hose lines with some slack, 

follow the natural curve of the hose line and obviously 

avoid wear at points of abrasion and prevent 

kinks through the use of curved fittings.” 

Sometimes there really is no other way of installing 

hose lines. What should you do then? 

“The operator or manufacturer should appreciate 

that such a hose line will not be installed to optimum 

effect! Users must then inspect and document 

such lines more frequently under their risk assessment 

programme. There are manufacturers who 

specify that hose lines subject to such high stresses 

have to be replaced after just two years. Operators 

should comply with this without fail.” 

Recommendation according to DIN 20066 : 2002-10: 

For how long hose lines can be utilised? 

maxium of 4 years 

Age of hose line 

A 

A = manufacturing date of hose material 

B 

maximum 2 years 

time of storage 

for hose line 

Well, it’s no doubt true to say that not every 

employee at a company can go and check the 

hose lines installed in a hydraulic system? 

“Here the operator must allocate this task to a socalled 

Qualified Person – this is also specified by 

law – someone for example who must have undergone 

relevant training in this regard. Seminars also 

dealing with hose lines are organised by various 

institutions such as the Verband der Baumaschinen-Ingenieure 

und -Meister (German Association 

of Construction Machinery Engineers and Master 

Craftsmen). As an active member in this association 

HANSAFLEX has already taken part in these seminars 

on several occasions. Direct training is also 

available at the HANSA-FLEX training centre for 

Qualified Persons responsible for line engineering 

and accumulators. As a hydraulic service provider 

we additionally organise various seminars at the 

centre about the basic principles of fluid technology 

for customers, our own staff as well as people 

who are not customers of ours. Here a Qualified 

Person from the field of line engineering will not 

only learn about the correct usage of hydraulic hose 

lines, pipework and connection technology but also 

the relevant legislation, standards and directives. 

Hydraulic oil of course plays a role here, as whatever 

contaminates oil presents a risk to hydraulic 

hose lines as well.” 

One thing we should never forget: hose lines are 

not components that will last for ever! “But their 

service life can be considerably extended by design 

and installation according to the requirements as 

well as appropriate inspections including documentation 

– something that simultaneously provides 

legal certainty”, comments Ulrich Hielscher, 

recommending that hose lines are replaced after six 

years at the latest. 

B = manufacturing date of hose line 

maximum of 6 years 

Specified period of usage 


HYDRAULIKPRESSE 25


GENERAL MANAGER TECHNOLOGY 

More than just a technician 

Axel Tammen takes a global view 

solution designed to meet their requirements.” Axel 

Tammen considers the company’s cooperation with 

customer Terex O&K Mining in Dortmund to be an 

example of this type of work. HANSA-FLEX was 

asked whether the company as a preferred supplier 

would be capable of continuously delivering 

32,000 parts complying with the specifications of 

Terex O&K. Here the Technical Department provided 

Sales with efficient back-up and helped shape the 

“works in works” concept. 

HANSA-FLEX has developed into a complex business 

in terms of applied manufacturing processes and 

products. To ensure a sound technical basis for success, 

the firm has created the position of “General 

Manager Technology” and appointed a key figure 

with international experience to this role. Since 1 April 

2007 Axel Tammen has been employed as “General 

Manager Technology” at HANSA-FLEX’s Head Office. 

In this period Mr Tammen, a graduate engineer for 

precision mechanics, has assisted the company in its 

transformation towards becoming a system partner 

for fluid technology. Here he has shown plenty of 

initiative by introducing an optimised process for 

the approval or parts and suppliers and so extending 

the existing quality management system. “We 

intend to further professionalise the entire product 

and service quality process,” comments Axel 

Tammen, “in order to mould HANSA-FLEX into a 

company offering uniform high quality standards.” 

This engineer, who was born in 1962, has extensive 

experience in the hydraulics sector, something that 

is reflected in his involvement and management of 

national and international standardisation committees. 

Optimum customer satisfaction is his philosophy. 

But to achieve this a rethink will be necessary 

in many cases: “in all departments” stresses the 

Technology Manager, noting that his own is no 

exception. “Here we must develop our expertise as 

advisors and a department with inherent responsibility 

for technical solutions and offer support to 

all HANSA-FLEX branches and specialist centres of 

competence in terms of customer orientation.” 

It is not enough, says Axel Tammen, to have all 

technical aspects under control. He therefore asks 

all staff to “simply look beyond their own noses”. 

Axel Tammen also demonstrates this approach in 

his spare time. As a keen amateur photographer 

who adores taking pictures of animals he uses the 

latest camera equipment for his breathtaking shots 

of South Africa’s Kruger National Park. He adds 

however, “if such photos are to come off, I need to 

know how animals behave in the wild”. 

The adventure of technology 

In the world of work this means “applying the expertise 

of the specialists from the Technical Department 

so that customers are offered a future-proof 

According to Axel Tammen, this support function 

will give rise to even greater potential in the 

Technical Department in the future. “Customers are 

presenting HANSA-FLEX with increasingly complex 

problems,” one reason why he wants to involve 

this department in the overall development of the 

company more closely. “We are already pretty good, 

but we want to be even better, and this can best 

be achieved if customer satisfaction is increased.” A 

philosophy that is going to be used by Axel Tammen 

to make a few more changes at HANSA-FLEX. 

But for the time being it is the XWORLD Tour with 

its exciting offroad routes that is occupying his 

thoughts. “This is pure delight. I can only hope that 

every participant will enjoy this fantastic experience.” 

26 


ISSUE APRIL 2008

QUIZ | FIGURES & FACTS | PREVIEW 

H 

Win one iPod touch 

Simply answer our quiz question and the iPod touch 8 GB could be yours! 

Please send the answer in by Email to ma@hansa-flex. 

com or by post. Please do not forget to indicate your 

name and your post adress. The deadline for entries 

is the 30. May 2008. One entry per participant will be 

considered for the draw. Terms and conditions apply for 

legal recourse and liability. A cash payment for the prize 

is not possible. Employees and members of HANSA-FLEX 

are excluded from participating. 

iPod touch, 8 GB (holds up to 1750 songs), 3.5-inch 

(diagonal) widescreen Multi-Touch display; earphones, 

USB cable, dock adapter, software iTunes for 

Mac & Windows; PC system requirements: USB 2.0 

port, Windows Vista or Windows XP Home or Professional 

with Service Pack 2 or later, iTunes 7.6 or later; 

Mac system requirements: USB 2.0 port, Mac OS X 

v10.4.10 or later; iTunes 7.6 or later. 

Question: 

How long does one have to wait to see 

whether the casting of a MAN Diesel 

engine succeeded? 

A: 17 hours 

B: 17 days 

C: 17 weeks 

Answer edition 02/08: 

B: On 10th day – Winner: M. Schmidt, Mannheim 

and D. Stevens, Emden 

Openings 

January 

HANSA-FLEX Hydraulik GmbH Industriestr. 2 97616 Bad Neustadt Germany 

February 

HANSA-FLEX Croatia d.o.o. 48000 Koprivnica Croatia 

March 

HANSA-FLEX Hydraulik GmbH Talsperrenstr. 6 08606 Oelsnitz Germany 

Figures & Facts 

Total 

Germany 

326 178 

Anniversary 

April: 

May: 

HANSA-FLEX Brno/Czech Republic 5 Years 

HANSA-FLEX Frechen/Germany 15 Years 

HANSA-FLEX Kaunas/ Lithuania 10 Years 

HANSA-FLEX Samtens/Germany 10 Years 

HANSA-FLEX Sontra-Wichmannshausen/Germany 5 Years 

HANSA-FLEX Willich-Münchheide/Germany 10 Years 

173 

97 

The following topics will be run in the next edition... 

Preview 

06/08 

Mützelfeldtwerft 

In conversation with 

HANSA-FLEX branches 

Training centre 

BenTec 

New at HANSA-FLEX 

High sea tug in new dimension 

Frank Schmidt, export manager HANSA-FLEX 

Tempelhof and Madrid 

Air in the oil and the consequences 

Drilling rigs for challenging use in Siberia 

Industrial hoses from Telfs 

Editorial deadline: 23. Mai 2008 



27

Participation limited – book now! 

Advert

hydraulik - HANSA-FLEX Hydraulics Canada Inc.

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?