HYDRAULIKPRESSE - HANSA-FLEX Hydraulics Canada Inc.

12/07 

06 

12 

14 

Issue 12/2007 

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HYDRAULIKPRESSE 

Mining excavators 

Giants in oil sand 

Everything from one 

source 

Moulded hoses now 

also available 

HANSA-FLEX Czech 

Republic 

Development in fast 

motion 

Mining excavators 

Giants in oil sand 

Page 6

CONTENT | IMPRESS 

Content 

Editorial 03 

XWORLD Off -Road Events – With a tiger on rough terrain 04 

Mining excavators - Giants in oil sand 06 

In conversation with Diethelm Kappe 10 

Everything from one source – Moulded hoses now also available 12 

HANSA-FLEX Czech Republic – Development in fast motion 14 

HANSA-FLEX branch Nordhausen – A region undergoing upheaval 15 

Getting to the top with Magaziner – Adaptation of high-lift trucks 16 

HANSA-FLEX Switzerland – Hydraulics service by helicopter 18 

Oil treatment made easy– An ABC: Which hydraulic fl uid is right? 20 

20 successful years in the hydraulics sector – Change in management at Willmann 22 

Quiz, Figures & Facts, Preview 23 

02 


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-fl ex.com 

www.hansa-fl ex.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. 

ISSUE DECEMBER 2007

ISSUE DECEMBER 2007 

Dear Reader, 

2007 is drawing to a close, and it has been a successful year for HANSA-FLEX. New branches both at home 

and abroad have been added to what is already a dense network. We only recently opened our 300th branch 

of the company, guaranteeing even greater proximity to the customer. And with FLEXXPRESS we are quickly 

on hand to help wherever there are urgent problems with hydraulics. 

Our customers tell us time and time again that besides such proximity and our strong focus on service, it is 

above all the outstanding commitment shown by all HANSA-FLEX staff that strengthens the reputation of 

our company as a system partner for hydraulics. Our clientele acknowledge such customer orientation by 

placing new orders and endowing us with increasing responsibility. Responsibility we are happy to take on 

as customer proximity is our guiding principle. 

A growth rate of more than 15 percent in 2007 speaks for itself. We are making every eff ort to safeguard such 

growth through development of the company. This also includes extending our product range. One new article 

in our programme is HANSA-FLEX moulded hoses, which we not only stock in many diff erent sizes but can 

also be manufactured according to customer specifi cations. You can fi nd out more on page 12 of this issue. 

We continue to do everything possible to make sure that all customers are fully satisfi ed with the support 

they receive. Whether extracting potash in Thuringia, at a diamond mine in South Africa or mining oil sand 

at an open pit in Canada. Whether quickly sending out a replacement hose line or off ering support to OEMs 

with fi nished subassemblies ready for installation directly on site. 

With our customer Terex Mining we are even going a step further. On page 6 we describe a tailor-made 

solution and show how HANSA-FLEX can off er effi cient help to its OEM customers directly at their works 

with the prompt manufacture of hose lines or curved pipes and a good stock of parts. HANSA-FLEX develops 

such service packages carefully tailored to the requirements of each customer in close cooperation with the 

company concerned to help them cut costs and also boost productivity and added value. 

As 2007 moves into 2008, we should like to thank our staff for their hard work and commitment giving new 

impetus to customer proximity. We also thank our customers for the trust they have put in our company. We 

wish you all health and success in the coming year. 

The Management Board 

The managing directors 

FOREWORD 

Editorial 

Uwe Buschmann Thomas Armerding 


03

XWORLD 

Mud splashes against the windscreen. The massive 

tread of the tyres digs its way forward through the 

tough morass. Each pothole is deeper than the last. 

The path between the trees narrows, becoming more 

and more bumpy - a trial of strength for both the 

drivers’ nerves and the axles of the off -roaders. And 

now they have to concentrate and make sure they 

don’t get stuck! 

To date the people taking part in the XWORLD Off - 

Road Events have been able to enjoy such adventurous 

scenarios. Before the fi rst stage of the tour 

starts in March 2008, staff , partners and external 

guests will have had the opportunity to try out the 

qualities of the upgraded Toyota Land Cruisers far 

away from the road. Since this February there have 

been over a dozen off -road events and test drives 

off ering the chance to experience the XWORLD vehicles 

live. A comfortable interior, a powerful 173 

hp engine, permanent four-wheel drive and special 

equipment for the tour will guarantee safety and 

enjoyment in each car. Whether equipped with a 

“snorkel” for driving through water, a cable winch 

or GPS navigation plus altimeter – the XWORLD vehicles 

are not mass-produced items off the shelf but 

special custom vehicles designed to cope with the 

high demands of the diff erent stages. 

Testing in an opencast pit 

The jungle-green Toyota Land Cruiser approaches 

the high sand dune covered with reed in fi rst gear. 

The challenge: The XWORLD off -roader must force 

its way up the steep slope without swerving or worse 

still, tipping over. The damp sand slips and slides, and 

with it the rear of the vehicle. The wheels slowly dig 

themselves higher and higher in the tracks up the 

dune. Putting your trust in the vehicle with a tiger 

on its side is a real thrill. And the off -roader actually 

manages to negotiate the crumbling slope without 

diffi culty. 

4 

XWORLD Off -Road Events 

With a tiger on rough terrain 


The fi rst test drives in testing terrain were performed 

by Enrico Kieschnick and the XWORLD project team 

at the beginning of 2007. The ideal spot for this 

was the disused opencast mine of Meuro near 

Senftenberg and Großräschen in Brandenburg. On 

this enormous area of land the off -road vehicles 

showed what they could do for the fi rst time on 

the occasion of the HANSA-FLEX regional manager 

meeting in March. In the middle of October 2007 

it was then the turn of the trade press to try out 

all XWORLD automobiles in a one-day event held 

at the mine. Verdict: The cars can cope with the 43 

stages through Europe and Asia! 

Grey hills as far as the eye can see. Deep gashes run 

down the slopes. The sky-blue Toyota sporting a 

panoramic view of the Himalayas disappears in a 

cloud of coal dust as it approaches a jagged edge between 

boulders. It suddenly lurches forward but the 

passengers are safe and secure in their seat belts. The 

vehicle slips and rolls in the loose sand until it gets 

going again a few metres later on, shortly afterwards 

ploughing through a fi eld of grass as tall as a man at 

high speed. 

Learning how to drive off -road 

Thrills and a surge of adrenalin are part of every 

event like the obligatory splashes of mud on trousers 

and jacket. The spectacular off -road events 

are however specially designed to familiarise drivers 

with the handling of off -road vehicles in general 

and more specifi cally, with the XWORLD Toyota 

Land Cruisers. “When driving off -road, there’s a 

whole load of things to consider. Even experienced 

car drivers need to fi rst learn how to handle our 

specially equipped XWORLD vehicles,” comments 

project manager Enrico Kieschnick. Together with 

HANSA-FLEX employee Roelof Wittler, the two men 

already form a well-rehearsed team of instructors 

thank to extensive special training. They are responsible 

for the initial briefi ng beforehand and 

ISSUE DECEMBER 2007

keep an eye on drivers throughout the entire event, 

in some cases remaining in contact by radio. “To 

start with, most are impressed by the technology 

and size of the vehicle, but this is generally forgotten 

after a few laps on site and the fi rst successful 

manoeuvres. Afterwards, everyone is delighted at 

what the cars can do.” 

On the fi rst major test drive in May 2007 the participants 

set off punctually over the Alps, heading for 

the Balkans to attend the 5th HANSA-FLEX football 

tournament in Croatia. In the Tyrolean mountains 

the suitability of the vehicles for long-haul driving, 

the tyre-wheel combination and chassis tuning 

were put to the test. The vehicle technology managed 

the over 1500 km section to Split with fl ying 

colours. In the subsequent football tournament in 

the blazing sunshine the HANSA-FLEX players from 

Germany had to content themselves with a successful 

third place against the fl eet-of-foot Czechs and 

the home team from Croatia. 

Murky brackish water slops against the white sandy 

beaches of the little island on the driver’s door of the 

South Sea Land Cruiser. The curtain of reed grass 

parts under the light bow wave ahead of the bonnet, 

off ering a glimpse of the nearby bank. The off -roader 

continues rocking its way forward through deep furrows 

and underwater craters. The water level now 

starts to fall, and the bank is reached at long last. The 

passengers’ feet remain dry but reeds are still caught 

in the radiator grille. 

Until the start of the tour in March 2008 another 

series of diff erent off -road events and show dates 

are planned. Until then the XWORLD Toyota Land 

Cruisers will cause a stir on German roads. The detailed 

XWORLD brochure will give you a taste for 

adventure. 


Just look on www.xworld.cc or call +49 – 661 - 440 

77 27 70 to request your own copy. Every trip will offer 

its very own adventures and diff erent highlights 

in terms of the scenery. Certain XWORLD stages are 

proving very popular so you shouldn’t hesitate if 

you are interested in taking part. 

Katharina Bader 

PRG Werbeagentur GmbH 

XWORLD 

HYDRAULIKPRESSE 5

TEREX GMBH 

In the search for crude oil rising oil prices and a foreseeable 

scarcity of resources have now prompted the 

exploitation of sources which were not previously lucrative 

enough. One example of this is the enormous 

oil sand fi elds at Fort McMurray in Canada. 

The province of Alberta contains around one third 

of the world’s available stocks of oil sand, which is 

mined at open pits by mighty crawler excavators. It 

is here that North America’s largest crude oil producer 

Syncrude Canada Ltd. (SCL) operates three 

opencast mines. Gigantic RH 400 mining excavators 

from Terex O&K are used to extract the oil sand. 

Terex GmbH based at Dortmund, a successor company 

to O&K AG founded in 1876, has repeatedly set 

milestones in the development of hydraulic excavators 

and specialises in extraction and conveying 

at opencast mines. At Fort McMurray not only hydraulic 

but also cable-operated and bucket-wheel 

6 

Mining excavators - giants in oil sand 

„Works in works“ - a tried and tested concept 


excavators are in use. Among them is the RH 400. 

With an operating weight of some 1,000 tons it is 

the world’s largest hydraulic excavator, with jumbosized 

dimensions. The excavator bucket alone has a 

capacity of 45 cubic metres, able to handle around 

100 tons of oil sand in a single pass. This calls for 

enormous forces - something that the RH 400 can 

deliver thanks to an engine output of 4400 HP and 

hydraulics that can cope with operating pressures 

of up to 310 bar. Oil sand can be mined in winter 

at - 40 °C when the ground is frozen rock-hard, but 

also in summer at + 40 °C when the oil sand has 

become a stringy mass. 

The extracted oil sand is then loaded onto gigantic 

heavy-duty trucks with payloads of up to 360 tons, 

which take it away for processing, fi nally resulting 

in the coveted crude oil. Four buckets from a RH 

400 will fi ll a heavy-duty truck. The mining excava- 

tor is controlled from the third fl oor so to speak. It 

is at this level that the driver’s cab is to be found, 

equipped with a control panel as well as a kitchenette 

complete with microwave and area for relaxing. 

The precise control system is designed to ensure 

easy operation although the skill of the driver 

also plays a key role here. Surprisingly, women are 

now increasingly to be found in this job: Experience 

has shown that they handle their machines with 

greater fi nesse. 

Ordered at short notice, delivered 

promptly 

A new RH 400 from Terex O&K is already scheduled 

to go into service at one of the three oil sand deposits 

in Alberta in January 2008. The time scale 

from ordering the mining excavator from the German 

manufacturer to commissioning is rather 

tight. Nowadays the construction of such mighty 

“workhorses” must be performed in record time. 

Once a mining company has decided to exploit 

a new oil fi eld, it cannot wait months for delivery 

of the machine required. For Terex O&K as the 

partner to the mine operator this makes high demands 

on its readiness to deliver. There must be 

no delay in assembly under any circumstances. 

Terex O&K therefore expects each subsupplier to 

off er special services, something that naturally 

also applies to the manufacturers of the hydraulic 

connecting elements. The completed excavator is 

based on designs, drawings and parts lists from an 

existing model but this was last built by Terex O&K 

three years ago - mining excavators of these dimensions 

are not mass-produced on an assembly line. 

As technical progress has not stood still since then, 

technological advances must of course also be taken 

into account and incorporated during construction 

of the machine. This may involve new units with 

modifi ed connections or new routings for pipes and 

hose lines, which have come about from the experiences 

evaluated by the operator over the last few 

years. In such cases fi ttings need to be changed, 

as well as nominal widths, with pipe manifolds 

ISSUE DECEMBER 2007

undergoing redesign, etc. For the hydraulic hose 

lines alone, some 150 diff erent types are installed 

in the RH 400, with nominal widths ranging from 

4 to 204. In addition to the various pipes, the RH 

400 excavator also includes 900 metres of hoses, 

containing more than 13,000 litres of hydraulic oil. 

To build jumbo-sized machines like the RH 400 in 

record time, fast solutions are required, so making 

high demands on the fl exibility of the hydraulic 

hose line supplier due to short-term planning. And 

HANSA-FLEX recently took on this role. 

Since 1 July 2007 the hydraulics service provider 

from Bremen has been represented at Terex O&K 

with its own on-site production facility. The works 

in works concept used there gives HANSA-FLEX the 

necessary fl exibility to make changes to components 

at short notice whenever required. 

Re-orientation calls for change 

Cooperation between Terex O&K and HANSA-FLEX 

came about after work was disrupted on the installation 

sites at Terex O&K following major increases 

in production which caused delays in delivery with 

various suppliers. The provisioning time for hose 

lines was to be slashed from one week to one day 

in order to cater for the ever-growing customer 

demands. Supply in its existing form was no longer 

suffi cient with short-term changes to components 

and increasingly tight delivery times for spare parts. 

Terex engineers Andreas Bruns and Frank Gorczak 

quickly made up their minds and set off to fi nd suppliers 

who could guarantee to deliver on the dot. 

The search took Andreas Bruns to HANSA-FLEX’s 

Oldenburg branch, where he showed a strong interest 

in the production of hydraulic hose lines. 

In their discussions it quickly became apparent to 

branch manager Jens Bruhn that this was a potential 

customer who was after fundamental solutions 

according to his specifi cations. He informed key 

account manager Matthias Henke at HANSA-FLEX’s 

Head Offi ce about this contact without further ado. 

He called Terex Lean Manager Andreas Bruns directly, 

and May 2006 then ushered in a period of famil- 


iarisation for the two companies. In the following 

weeks HANSA-FLEX teamed up with Terex O&K to 

draw up a concept providing for the 9,000 diff erent 

articles required for the hydraulic excavators in the 

specifi ed quality and guaranteeing 100% availability. 

Including hose lines in various nominal widths 

and with a whole range of special fi ttings, stainless 

steel pipes for the air intake system, hoses for the 

air conditioning, special steel parts such as pump 

fl anges and pipe manifolds with unusual dimensions 

and geometries, screw fi ttings and mountings. 

A winning concept 

HANSA-FLEX was not only able to supply all that but 

also demonstrated the fl exibility and focus on service 

required by Terex O&K. In line with its philosophy 

of customer proximity HANSA-FLEX declared itself 

willing to set up an individual workshop for this 

cooperation, including a complete production line 

to manufacture hose lines of all dimensions at short 

notice on Terex O&K’s site in Dortmund, as well as 

a warehouse stocking the 9,000 associated article. 

This solution guaranteed compliance with the 

specifi ed delivery time of just one day: The decisive 

criterion for Terex O&K! With this so-called “works 

in works” concept HANSA-FLEX has demonstrated 

its readiness to fully engage with the customer’s 

production processes, something that of course not 

only calls for the willingness to run a two-shift system 

but also to provide direct help with assembly: 

On site HANSA-FLEX staff measure the dimensions 

of the hose lines, establish the angle of rotation for 

fi ttings and manufacture the parts in the shortest 

possible time. Keeping to their word: If delivery has 

been promised within three hours, it will be there 

in three hours! 

Once this fundamental willingness to cooperate 

had been established, everything happened very 

quickly. 

TEREX GMBH 


TEREX GMBH 

Ready to go in minimum time 

Ralf Vogeler, technical expert at HANSA-FLEX’s 

Head Offi ce, took over the responsible task of comparing 

all Terex specifi cations with HANSA-FLEX’s 

delivery programme and ensuring technically fl awless 

solutions. This involved analysing all available 

engineering drawings and parts lists as Terex O&K 

did not want to incur costs for new components 

approvals so that cooperation could get off to a 

smooth start. The result was impressive, and buyer 

Frank Gorczak was able to use these analyses to 

check that HANSA-FLEX fulfi lled all expectations 

as the supplier. “We opted for the company who 

off ered us the greatest certainty in terms of supply 

with its focus on service, product quality and avail- 

8 


ability of materials.” However, it is not only troublefree 

work processes that speak for HANSA-FLEX, but 

also certifi ed quality documented according to EN 

DIN ISO 9001 and by Germanischer Lloyd. 

To ensure that everything was prepared for the 

start of operations in the shortest possible time, 

the Sales department in Bremen took over coordination 

of the project, appointing Matthias 

Henke as project manager. Following conclusion 

of the contract in December 2006, the new 

HANSA-FLEX branch was opened in July 2007 at Terex 

O&K by Thomas Armerding, managing director of 

HANSA-FLEX Hydraulik GmbH, and Dr. Heribert 

Bussmann, managing director of Terex GmbH. 

A lodger rigged out in red and 

white 

From this date the “works in works” concept has 

proved a hit. The seven HANSA-FLEX staff employed 

at the works are housed in a 1,300 m2 hall right 

next to the installation points. With the help of fi tters 

from ThyssenKrupp Industrieservice (TKIN) the 

hall was specially tailored to the requirements of 

HANSA-FLEX’s production processes, the machinery 

and electrics were installed and the entire facility 

of course painted in the colours of HANSA-FLEX’s 

Corporate Identity. The layout of the machines and 

storage areas was planned by key account manager 

Ralph Rehberger, who will in future also be 

in charge of other tasks such as the Cost Reduction 

Project in cooperation with Terex O&K. This project 

forms part of the contract with Terex O&K and is 

meant to cut procurement costs for the excavator 

manufacturer within 30 months. 

It involves for example suggestions how to optimise 

line engineering, e.g. by improving routings, 

minimising fi ttings and installation eff ort with new 

solutions and streamlining parts lists. The customer 

is free to implement the suggestions developed 

HANSA-FLEX as required. The advantages of having 

a workshop directly on the customer’s site are 

obvious and made themselves felt after just a few 

weeks. HANSA-FLEX off ers just-in-time delivery, 

something that is a key factor for Terex when it 

comes to complying with assembly times. In addition, 

the high level of contact on site provides scope 

for close cooperation. When there were design 

changes in the length dimensions and angles of rotation 

for suction line fi ttings on the world’s largest 

hydraulic excavator, a solution was quickly found. 

The staff reporting to production manager Marius 

Vennemann and his deputy Jörg Schulmeistrat 

made precise measurements of the excavator and 

soon afterwards the required connecting elements 

were ready for installation. And proved to be an 

exact fi t: For hose lines with the nominal width of 

204 there is almost no leeway for correcting errors 

in geometry on installation. 

ISSUE DECEMBER 2007

From the warehouse directly to 

the oil sand 

Stockkeeping is also in the hands of the hydraulics 

specialist from Bremen, so allowing Terex O&K to 

scale down its own supplies of hydraulic connecting 

elements to zero and thereby cut costs. The 

components required are arranged in trolleys by 

HANSA-FLEX so they are ready to hand for the fi tters 

at their individual workstations. Here the HDS 

high-pressure hose lines are also included in the 

deliveries. 

The close cooperation between HANSA-FLEX and 

Terex O&K is demonstrated every morning when 

a work scheduling meeting is held at Terex O&K, 

attended by managers from Job Planning, Procurement, 

Design and Quality Assurance in order 

to assess the level of progress at the installations 

points and to determine action for ensuring work 

continues swiftly. The members of the HANSA-FLEX 

team are also present so are able to quickly respond 


to every requirement of Terex O&K without wasting 

time. The process will be optimised even further by 

the changeover to an electronic ordering system in 

2008. The paperless system will speed up the ordering 

process as it no longer involves manual system 

inputting, so ruling out incorrect delivery due to 

data entry errors or misunderstandings. 

With the works in works concept HANSA-FLEX of 

course also provides backup to Terex’s customer 

TEREX GMBH 

service department, which supplies the spare parts 

required for the mining excavators from Dortmund 

that are used all over the world. Mining excavators 

are the key links in the logistics chain for oil sand 

extraction and therefore have to function without 

interruption as far as possible. Terex O&K can now 

off er fast help, with backup from HANSA-FLEX’s effi 

cient warehouse in Dortmund. 


IN CONVERSATION 

Over 20 years of service at HANSA-FLEX, to start with 

at the workshop, then as a member of the fi eld team, 

followed by a position as branch manager. Now four 

years spent as regional manager for the branches 

of Boff zen/Höxter, Korbach, Paderborn, Blomberg, 

Warburg and Lemgo. Diethelm Kappe is a man who 

combines theory and practice to come up with customised 

solutions. 

He was recruited to the company in Boff zen by Peter 

Weidtkamp Senior in 1986 and initiated into the 

10 

In conversation with Diethelm Kappe 

„We can‘t manage without training“ 


world of hydraulics. In 1987 the dynamic growth 

enjoyed by HANSA-FLEX resulted in the founding of 

the Paderborn branch, where Diethelm Kappe was 

taken on at the workshop. Branch manager Hans 

Lohmann quickly spotted Kappe’s suitability for 

work in the fi eld and encouraged him to develop 

these skills. In 1999 he succeeded his mentor, taking 

over his position as branch manager in Paderborn. 

He became one of the fi rst regional managers 

in 2003 and since 2002 has also been responsible 

for internal auditing at the Group’s branches. He 

spoke to HYDRAULIKPRESSE about his career and 

the future of specialist staff . 

: Did your time working in 

Boff zen leave its mark on you? 

Diethelm Kappe: Oh yes, I owe an awful lot to Peter 

Weidtkamp Senior. I was very impressed by his 

aspiration to run the company like a family fi rm. He 

motivated us all with his strategic approach combining 

challenge and encouragement, so ensuring 

growth of the Boff zen Group. Since then I know 

how important it is to have committed staff . In the 

meantime the Boff zen Group has been taken over 

by one of the shareholders, Peter Weidtkamp Junior, 

with whom I enjoy a working relationship based 

on partnership. And this is also the case with this 

sister Sabine Weidtkamp. 

: You have a bond with 

Peter Weidtkamp Junior from having worked together? 

Diethelm Kappe: You are speaking about my 

time in Niederaula. Following a period of intensive 

training I worked together then with Peter Weidtkamp 

Junior, looking after the tunnel building 

sites for the ICE line with a mobile workshop. We 

were always on hand with a well-stocked assortment 

of parts so spare hose lines could be supplied 

without delay. The customer was impressed by the 

fast availability and focus on service off ered by 

HANSA-FLEX. Here we virtually acted as pioneers, 

with this experience being subsequently incorporated 

in the concept of the HANSA-FLEX mobile 

service centre. Today FLEXXPRESS off ers a range 

of mobile services, guaranteeing fast support for 

customers. 

: This was soon followed 

by a stint in the fi eld team? 

Diethelm Kappe: In those days at Paderborn 

Hans Lohmann realised that I not only have a good 

understanding of technology and am able to get 

to grips with a subject but also that I know how 

customers’ minds work and speak their language. 

I enjoy working outside the offi ce, not least as this 

meant I received training from “old hands” such as 

Horst Klarholz, Werner Rode and Jürgen Marx. Their 

experience and tips were often a great help to me. 

on training? 

: What value do you place 

Diethelm Kappe: We can’t manage without 

training - I too received systematic encouragement 

and support. Today the opportunities for training 

within the HANSA-FLEX Group are quite diff erent. 

For example, courses at the training centre or at 

the branches, as well as product familiarisation organised 

by suppliers. I set great store by systematic 

training for all staff in my region as the continuous 

growth shown by HANSA-FLEX calls for the strategic 

cultivation of junior staff at every level. 

We can only play an active role in shaping the future 

with qualifi ed staff . In the region we have four 

youngsters training in the wholesale and export 

sector as well as in warehouse logistics. They are 

fully involved in processes at the individual companies, 

where they learn to act on their own initiative 

and take on board our customer and serviceoriented 

approach from the very outset. One great 

idea is HANSA-FLEX’s initiative to train a hydraulics 

specialist – even providing a diploma. Our workshop 

manager in Paderborn, Hans-Josef Denzer, 

is due to complete this training course in Dresden 

next summer (2008). This will allow all staff to take 

on new responsibilities in the course of their career, 

including abroad. 

ISSUE DECEMBER 2007

specialists? 

: Does HANSA-FLEX need 

Diethelm Kappe: This issue also plays a key role at 

the meetings of the regional managers. Further development 

of the system provider concept means 

that we are on the lookout for specialist staff . After 

all, we want to ensure dynamic growth in terms of 

personnel. Staff who were at our side from the start 

will slowly be retiring and need to be replaced by 

competent successors. 

: Where will future development 

take the Group? 

Diethelm Kappe: I too have experienced the 

transformation from a supplier of spare hose lines 

to a system provider for hydraulics. This concept 

opens up new opportunities in the market, something 

that can also be seen in the increased sales. 

Customers appreciate our focus on service, and we 


want to optimise this further. Here it is a question 

of opening up new markets and making systematic 

use of the available opportunities to off er our existing 

customer base reliable support. By making 

things easier for them - off ering everything from a 

single source. We must actively communicate this 

message, for example the planning and manufacture 

of units or complete hydraulic systems extending 

to fi tting and commissioning at customers’ 

plants. 

I have also noticed a change in the approach of 

staff . If they were once satisfi ed with supplying 

the relevant spare part to the customer, they now 

adopt a strategic approach, drawing the customer’s 

attention to our services, including the supply of 

components or installation. And they look confi - 

dent when doing so as they have been trained and 

are thus able to off er customers profi cient advice. 

: And there are examples 

of this in your group. 

IN CONVERSATION 

Diethelm Kappe: Our off er of repairing cylinders 

in Boff zen means fast help for customers right away. 

If minor repairs are involved, for example replacing 

seals, this can be done in Boff zen by Andreas 

Meyer or Ansgar Block. More complex work is carried 

out in cooperation with the specialists based at 

HANSA-FLEX’s cylinder repair centre in Königshofen. 

: To what extent has 

X-CODE been incorporated here? 

Diethelm Kappe: Numerous customers are delighted 

about using this service module. For example, 

the automotive logistics company E.H. Harms 

in Paderborn. In the past a fi tter from Harms turned 

up at the branch in the morning, armed with a large 

box of old hose lines which needed to be replaced. 

Today a fax with the X-CODE numbers arrives fi rst 

thing. The spare hose lines are immediately manufactured 

to order and are ready for collection by 

lunchtime. 

Or the example of Benteler Automotive and Benteler 

Stahlrohr. There hose lines were subsequently 

marked with X-CODE on the production machines. 

This allows machine downtimes to be kept to an 

absolute minimum in the event of repair. And we 

even supply the spare parts to the customer using 

our service vehicle without any loss of time. Offering 

specifi c benefi t to customers: This is where 

HANSA-FLEX is successful. 


MOULDED HOSES 

When space is tight in machine construction, 

manufacturers will now immediately reach for 

HANSA-FLEX moulded hoses. HANSA-FLEX is rounding 

off its comprehensive product range with this 

new line: The fl uid technology system partner is now 

off ering moulded hoses that can be manufactured in 

any form, geometry and diameter and are an ideal 

addition to the tried and tested range of products for 

fl uid technology. 

Anyone who owns a car will know what we are talking 

about here: Moulded hoses are used for example 

to connect the radiator and the engine. And this 

is only one of many possible applications. Moulded 

hoses come in whenever pipes reach their natural 

limits. This is above all the case with complex installations 

when space is tight, calling for bending radiuses 

that are just not possible with pipes. In general 

moulded hoses can be used to join two parts 

together, for example, the fi lter to the transmission 

12 

Everything from one source: 

Moulded hoses now also available 


or the steering gear to the oil cooler, especially 

when the installation conditions call for bending 

radiuses that can only be achieved with moulded 

hoses. Such hoses can be manufactured in all forms, 

geometries and diameters and are suitable for use 

in very cramped spaces. This means that it is possible 

to guarantee a technically perfect installation 

even under diffi cult, cramped conditions, so in the 

end signifi cantly contributing to the wear resistance 

of systems. 

At the same time moulded hoses even out tolerances 

and as vibration dampers have a decoupling 

eff ect. They absorb vibration – for example from 

the engine – and so reliably prevents this from 

causing leakage or worse still, fractures. For this 

reason, such hoses are also fi tted in heavy mining 

excavators used at open pits. The powerful engines 

of these mighty vehicles, which are in non-stop 

operation 365 days a year, make the installation of 

moulded hoses absolutely essential as they absorb 

vibration and oscillation. HANSA-FLEX produces 

customised hoses to the exact specifi cations of 

the manufacturer. The man in charge here is Ralph 

Rehberger, who is the specialist responsible at 

HANSA-FLEX for the entire sector of moulded 

hoses. 

Individually moulded 

Moulded hoses can be tailor-made as an individual 

solution to the exact specifi cations of the customer. 

Something that is of advantage particularly with 

new designs, which generally call for individual 

solutions. HANSA-FLEX can off er its customers 

full service if required: From development of the 

moulded hose to sampling and transfer to serial 

production. If the customer does not supply the 

necessary space coordinates, HANSA-FLEX will also 

take measurements to determine the XYZ data. A 

moulding tool is then needed to manufacture the 

hose. With the data that have either been provided 

or measured HANSA-FLEX fi rst produces a so-called 

moulding mandrel made of steel or stainless steel, 

ISSUE DECEMBER 2007

whose geometry will create the hose geometry 

required. Vulcanised metal or rubber components 

can be incorporated or attached to realise almost 

any conceivable design or mounting alternatives – 

another advantage of moulded hoses. 

As moulded hoses are subject to particularly high 

stresses in terms of vibrations and bending loads, a 

long service life depends on lasting quality. For this 

reason HANSA-FLEX moulded hoses are produced 

from the material EPDM. Ethylene-propylene rubber 

is resistant to aqueous media and is therefore 

a popular choice for applications involving cooling 

water. This versatile material also off ers excellent 

resistance to ageing, weathering and ozone, and 

can be used in a temperature range from -50 °C to 

+150 °C. 

Basic range already in stock 

Besides the moulded EPDM hoses available from 

stock HANSA-FLEX also manufactures moulded 

hoses made of acrylonitrile butadiene rubber (NBR) 

from NBR/PVC cuttings according to the requirements. 

They are resistant to oil and traces of oil 

and are especially robust, non-ageing and fl exible 

as well. Chlorobutadiene rubber (CR) off ers good 

resistance to chemicals, ageing and ozone while 

acrylic-ethylene rubber (AEM) is characterised by 

good resistance to mineral oils, water and coolants. 

Epichlorohydrin rubber (ECO) has to be used 

for moulded hoses which need to simultaneously 

withstand temperatures of over 160 °C and the effect 

of fuels. 

Moulded hoses made of silicone are the choice if 

liquid media are to be conveyed with a high material 

or ambient temperature. As a fl exible material 

resistant to deformation they ey y w wi with wi with withstand t stand temperatures 

of up to 180 °C on n a a 

llong-term 

ong-term 

basis, and even to 250 °C for fo or r 

brief periods. 


With its wide range of moulded hoses HANSA- 

FLEX can now off er customers everything from one 

source. HANSA-FLEX’s warehouse at the Walldorf 

branch contains a basic range of all types of moulded 

hoses for standard applications such as coolants, 

ready for immediate delivery. From an internal 

diameter of 20 millimetres up to 78 millimetres. 

These robust long-lasting hoses are available from 

stock via all HANSA-FLEX branches. 

MOULDED HOSES 


BRANCHES 

HANSA-FLEX Czech Republic was founded in Prague 

in 1995 with a branch based on the industrial site 

of Prazská strojírna A.G., which initially provided 

a hydraulics service for the entire region of Central 

Bohemia. 

It quickly managed to win over customers with the 

level of quality supplied, a well-stocked warehouse 

and a 24-hour service. Its clientele soon included 

numerous transport companies and building contractors 

involved in construction of the new traffi c 

routes and lines of Prague’s underground railway. 

The company then opened a second branch in 

Prague in 1999 with a staff of four. Today this offi 

ce is responsible for managing all other branches 

based in the Czech Republic. It is headed up by Rudolf 

Melc. Since 2002 HANSA-FLEX’s Czech Republic 

Group has also included branches in Ústí nad Labem 

and Liberec. The branch in Liberec, which is managed 

by Pavel Kovarík, is housed in the building in 

which the well-known car designer Porsche was 

14 

HANSA-FLEX Czech Republic 

Development in fast motion 


born. Together with the branch in Ústí nad Labem 

managed by Rudolf Reichelt it is responsible for 

off ering service to North Bohemia. The Ústí branch 

was also involved in the tunnelling work for the 

motorway network between Prague and Dresden. 

Since 2003 the traditionally dynamic industrial region 

of Brno has been home to one of the company’s 

most successful branches in the Czech Republic. 

Here Marian Bednarík and a team of two devote 

themselves to the business of hydraulic components 

and operate as an OEM for a major exporter 

in the oil rig sector supplying the whole of Europe. 

In the region of Pilsen, which specialises in mechanical 

engineering, Michal Urban manages a 

branch founded in 2004. Besides its hydraulics service, 

the branch supports the international Ingersoll- 

Rand organisation with compressor production as 

original equipment. With the help of Karl- Heinz 

Loose from Head Offi ce in Bremen, Pilsen is responsible 

for supplying curved pipes, produced by 

HANSA-FLEX Weixdorf. 

2005 saw the addition of a branch in Pardubice, 

which is managed by Miroslav Vencl. This region 

is dominated by chemicals production. Its bestknown 

product is Semtex, a plastic explosive for 

commercial blasting. The customers of the branch 

not only include companies from the chemicals industry 

but also agricultural fi rms and building contractors 

involved in development of 

the Prague - Ostrava ava 

rail corridor. 

Chodov near 

Karlovy Vary 

was the site chosen 

for the next 

branch founded 

in 2006. Here 

branch manager 

Zdenek Kozel 

was faced with 

the major challenge 

of in particuu- 

lar winning over customers from the mining sector 

in the coal basin of North Bohemia and Most. 

The region of Ostrava, once a centre for steel in the 

republic, has also shown highly dynamic growth. 

The demand for hydraulics services is growing 

there, so prompting HANSA-FLEX to open another 

branch there in 2007 under the management of 

Jirí Stanovsky. This year also saw inauguration of 

the tenth branch in the industrial region of Zlín, 

where the machine construction sector is currently 

undergoing regeneration. This branch is managed 

by Martin Panácek. The dense network of branches 

in the Czech Republic headed up by Jaroslav Kratochvil 

is now aiming to further improve the quality 

of services and add to this range according to the 

requirements of customers. The FLEXXPRESS vehicle 

based in Prague is set to be joined by others 

in these regions. New services such as X-CODE, 

the ISSO standard and of course constant expansion 

of the product range are all communicated by 

HANSA-FLEX Czech Republic at exhibitions and fairs, 

in trade journals and - it goes without saying - by 

HYDRAULIKPRESSE. 

ISSUE DECEMBER 2007

From 2008 the night will end at 4.00 am for staff at 

HANSA-FLEX’s Nordhausen branch. Introduction of 

a two-shift system will then mean getting up early. 

This is the only way to cope with customer requirements. 

The upheaval underway in an entire region at 

the southern edge of the Harz mountains in the north 

of Thuringia is apparent. 

In Nordhausen branch manager Bernd Bady and his 

team of two staff , who will soon be backed up by 

the addition of two other colleagues, not only look 

after over 1,000 customers in the agricultural sector 

and industrial fi rms in the region both large and 

small, but act as an OEM to manufacturers known 

throughout Germany. One of these is Schachtbau 

Nordhausen GmbH, a specialist contractor with 

over 105 years of tradition in the techniques of mining 

and underground working, as well as the use of 

modern building methods. This company operates 

in the mining sector in addition to bridge building 

and civil engineering and is also involved in environmental 

technology. 

For centuries Thuringia has been known for the extraction 

of potash salt taking place in the region at 


BRANCHES 

HANSA-FLEX Nordhausen branch 

A region undergoing upheaval 

depths between 600 and 1000 metres. Although in 

the past many potash mines have seen retreating 

and shutdown, the plan is to once again mine potash 

salt from 2009 – not least due to the increasing 

salt prices. With this taking place at a deposit 

containing at least 200 million tons of potash salt. 

This means that additional responsibilities are in 

store for HANSA-FLEX Nordhausen. For Schachtbau 

GmbH the branch operates as an OEM in the business 

area of undercarriages and upper decks for 

construction and mine vehicles, leaders and bodies 

on MAN drilling equipment. 

Maximator GmbH, a systems supplier for high-pressure 

and testing technology, hydraulics and pneumatics, 

also relies on support from Nordhausen. 

As an OEM, HANSA-FLEX ensures that the right hydraulic 

components go into test rigs for high-pressure 

applications used to check pressure, bursting, 

tightness and internal pressure, under the responsibility 

of fi eld team member Volker Weickert. Such 

test rigs are utilised in laboratories or R&D facilities 

or for quality control and incoming goods checks. 

HANSA-FLEX’s Nordhausen branch is currently managing 

a workshop container at the Höllbergtunnel 

building site near Bernterode on the B 80 / A 38. 

The customer working there has already relied for 

years on support from HANSA-FLEX and its dense 

service network at construction sites elsewhere in 

Germany and has benefi ted from good experience 

with the company. So it was a matter of course 

that the nearest branch at Nordhausen should be 

in charge of the workshop container at the tunnel 

building site in Thuringia. Works manager Bernd 

Bady and Volker Weickert are responsible for ensuring 

that this mobile container, which is relocated 

along with the tunnel building site, is adequately 

stocked with the spare hydraulic parts required on 

site at all times. 

The customer structure of the Nordhausen 

branch means that it has to call on the services of 

HANSA-FLEX’s special centres of competence time 

and time again when special hydraulic components 

or special pipes and fi ttings are needed. And when 

it is a question of sealing technology, unit manufacturing 

or plant engineering, the team from Nordhausen 

are happy to frequently call on the services 

and full range of benefi ts off ered by HANSA-FLEX’s 

numerous centres of competence. For example, the 

manufacture of hydraulic units required by Schachtbau 

Nordhausen for the off shore sector. 


MAGAZINER 

The logistics sector is booming, and globalisation is 

resulting in cargo handling that is not only showing 

continuous growth but also has to take place at 

ever-increasing speed. International trade is thriving, 

something that mainly benefi ts the stock management 

sector. Here acceleration of the processes involved 

calls for sophisticated storage systems, which 

need to fi t together smoothly in the interaction between 

rack and truck. 

16 

Getting to the top with Magaziner 

Adaptation of high-lift trucks 


This in particular applies to the latest high-rack 

warehouses with picking facilities, making use 

of special trucks. Magaziner GmbH, which was 

founded in 1975 and is managed by the owners as 

a family fi rm, specialises in the development, design 

and manufacture of combi narrow-aisle trucks. 

Magaziner originally made these industrial trucks 

– as they are offi cially known – for the brands 

Lansing and Linde: very stable and reliable vehicles 

featuring fl exible narrow-aisle technology. These 

special industrial trucks are characterised by their 

individual manufacture. “This means that we can 

specially tailor this equipment to the specifi c features 

of the customer’s warehouse”, enthuses Magaziner 

sales manager Hans-Jürgen Ebsen. While the 

competition frequently only off ers product versions 

in four sizes, Magaziner can supply overall widths 

ranging from 1,000 to 2,600 millimetres - in other 

words, especially narrow or wide vehicles, which 

with a length of 2,850 millimetres can also be extremely 

short and manoeuvrable. With this size 

the industrial trucks can be closely adapted to their 

subsequent application in terms of the design in 

increments of one centimetre – so allowing them 

to work equally well in narrow-aisle warehouses 

as in halls with large widths for bulky products. 

The adaptability of these trucks is of advantage to 

the operators of warehouses in the service sector in 

order to optimise quiet running and ensure ergonomic 

design for picking. 

An ideal combination 

Such variable adaptation is a convincing reason for 

customers to use this equipment. Magaziner only 

recently received a major order from a car manufacturer 

which ordered 70 trucks for the company’s 

logistics system. The enquiry involved narrow-aisle 

combi trucks as the manufacturer was already using 

picking equipment manned by a driver who 

rides up with the pallet to the storage location and 

can remove or transfer the goods to stock by hand 

as appropriate. This procedure not only brings ergonomic 

benefi ts for staff but also more eff ective utilisation 

of the space in the high-rise rack as pallets 

can be precisely positioned by operators. 

Where once there was often only room for three 

pallets because visibility from the ground was no 

longer very good at heights from six metres, the 

driver riding up with the truck can now store four 

pallets, so making better use of the capacities available. 

It is also easier to remove individual items 

from the pallets, also simplifying picking. 

ISSUE DECEMBER 2007

Narrow-aisle technology with so-called man-down 

trucks has been around for a long time – here the 

truck driver remains on the ground. In 1973 Magaziner 

was one of the fi rst manufacturers to combine 

the two systems including their respective benefi ts 

following joint discussions and planning with the 

customer in question. Particularly in the fi eld of 

automotive engineering the conveyance of parts of 

course needs to function smoothly, both in the case 

of complete pallets and individual components. 

The combi trucks are equipped as standard with a 

spacious and comfortable cab, which makes picking 

easier thanks to the narrow front railing. 

With annual sales fi gures of 250 narrow-aisle trucks, 

Magaziner has a market share of 25 percent in this 

sector and has become one of the key manufacturers 

of such special-purpose vehicles. Magaziner is 

the only company to build such combi trucks with 

a lift height of max. 17 metres and capacities of up 

to 2 tons. Such narrow-aisle trucks are even used 

in refrigerated warehouses storing foodstuff s such 

as fi sh, meat and frozen vegetables. Here trucks 

not only have to cope with a lift height of 17 metres 

- the temperatures of -30 °C also occurring in 

cold stores make high demands on the operational 

readiness of equipment. A true challenge for every 

truck. 

Truck masts are optimised by means of computerised 

design, so making them very lightweight 

with excellent visibility. The truck’s overall centre of 

gravity is set low to ensure that the vehicle is characterised 

by outstanding stability. Another important 

feature is a low mast weight as this is a basic 

requirement for high performance and low energy 

consumption. This means that complex electrical 

systems to stabilise equipment are basically not 

required in Magaziner trucks. 

Equipped for every application 

Magaziner is currently working on a special design 

for a combi truck that is to be used at a furniture 

logistics warehouse. As exhaust gases are to be 

avoided at this facility for reasons of hygiene and 


to protect the health of the people working there, 

Magaziner is designing its trucks as electric vehicles. 

It even off ers special-purpose industrial trucks 

in a version designed for explosive gas atmospheres 

in the chemicals industry. 

As Magaziner only sells to dealers, it receives its 

orders from their customers. They give the dealer 

specifi cations e.g. for the pallet size and fi lling 

height as well as the dimensions of the hall, asking 

the dealer to arrange for the maximum number 

of storage locations and to ensure they provide for 

fast handling. Magaziner then advises dealers according 

to these customer specifi cations, helping 

them to determine all parameters and translate 

them into an optimum design. g 

As a subsupplier HANSA-FLEX FLEX is naturally also dependent 

on this individual alconstruction procedure for trucks. s. Like its 

customers, Magaziner expects pects fast 

ability to deliver and makes es special 

demands on the hydraulics cs serviceprovider. 

With individual machines 

this of course also includes s advising 

on optimum design of the e line engineering. 

The timescales allowed for orproduction from placement of an n order 

to commissioning of a material 

handling vehicle are becoming coming 

ever shorter: A fast response onse is 

what is needed in the booming ooming 

logistics sector. HANSA-FLEX’s A-FLEX’s 

Hanover branch staff ed by y manager 

Carsten Daumen and his team eam has been in charge of 

Magaziner for almost 30 years ears and are used to providing 

the customer with extensive support. They 

ensure the immediate delivery ivery of hose lines ready 

for installation together with ith mountings. Although 

Magaziner has its own machines achines for in-house pro- production 

of hoses, HANSA-FLEX FLEX nevertheless also 

supplies it with the complete mplete hose material 

required. 

MAGAZINER 


HANSA-FLEX SWITZERLAND 

Hydraulics service by helicopter 

From a commercial enterprise to a strong partner 

The new name now makes plain what was clear to 

many customers long ago: HANSA-FLEX AG has become 

a high-powered hydraulics partner – for this 

reason it was offi cially named HANSA-FLEX Hydraulik 

AG in August 2007. 

Under the committed management of Paul Rentsch 

the former HANSA-FLEX AG has transformed itself 

from a commercial enterprise with hose line preassembly 

to a global hydraulics supplier. “And we also 

18 


express this with our change in name”, comments 

managing director Paul Rentsch. This transformation 

coincides with the off er of additional services. 

Here HANSA-FLEX’s fi tting team has already 

proved its worth under the toughest conditions, 

managing to successfully install and commission 

impressive hydraulic systems. For example, on the 

Sedrun site at the Gotthard Base Tunnel, where 

HANSA-FLEX was instructed by Marti-Technik AG to 

fi t and start up the hydraulic systems on concrete 

formwork carriages. When concreting the two tunnel 

sections, each with a diameter of around nine 

metres, a nozzle rotates around the longitudinal 

axis of the tunnel drilling machine and sprays the 

enclosed section with concrete. Here the resulting 

inner shell has to be as smooth as possible to allow 

the trains to subsequently travel through the 

tunnel at high speeds. Work at the Gotthard Tunnel 

is by no means an easy matter for HANSA-FLEX’s fi tters 

as the driving points can only be reached via an 

ISSUE DECEMBER 2007

access gallery some one kilometre metre 

in length. This means that 

every single component has to o 

be lowered from 1,300 metres es 

above sea level down to the he 

track height of 500 metres using ing 

an enormous lift. It must be possible 

to dismantle each machine ne so 

it will fi t into the lift. The logistics gistics 

have to be right as well. If a tool ool or 

screw fi tting has been forgotten, otten, 

this means going up to get and d coming 

back – something that takes kes up to 

two hours each time. And the last lift is 

at 10.00 pm. 

Our team of fi tters therefore turned up with a 

10-foot container and 1,500 metres of KP213 hose 

complete with swage nipples and screwed connections. 

In the tunnel the hose lines ines were measured 

up, preassembled and installed, d, followed by commissioning 

of the formwork system. Work that 

HANSA-FLEX’s fi tters have already eady carried out on 

several building sites, installing ing in total almost almost 

9,000 metres of hose line. Several eral hundred metres 

of piping were fi tted to the full ll satisfaction of the 

customer when HANSA-FLEX’s X’s hydraulics service 

was asked to modify / replace place the production 

equipment at Jansen Röhrenwerke. erke. 

When the mountain calls for 

FLEXXPRESS 

FLEXXPRESS has also been successfully introduced 

as a service in Switzerland, with the mobile hydraulics 

service fl ying into the mountains by helicopter if 

there is no other alternative. With the mobile workshops 

the service technicians have repaired many a 

hose line on the spot, so reducing downtimes and 

avoiding any loss of production. 


Here X- 

CODE naturally 

also 

contributed 

to clear identifi 

cation of spare 

parts. The The benefi ts 

of the coding system system 

when working in the 

Gotthard Tunnel need no 

special mention. HAN- 

SA-FLEX has recently 

started off ering its Swiss 

customers other services 

such as the inspection 

and maintenance 

of hydraulic systems, including 

oil treatment. A 

service that is of particular 

interest to customers 

with decentralised, regional 

production sites. 

HANSA-FLE X SWITZERLAND 


TRAINING CENTER 

In hydraulic systems the hydraulic fl uid or pressure 

medium is a decisive factor in determining whether 

a hydraulic system operates reliably and achieves a 

long service life. The use of fl uids in hydraulic installations 

calls for enormous knowledge and care. With 

the course subject “Hydraulic Fluids” HANSA-FLEX is 

helping to make customer customers 

more aware of how to 

handle hydraulic hydrauli 

fl uids. 

20 

Oil treatment made easy 

An ABC: Which hydraulic fl uid is right? 


HANSA-FLEX’s training manager Ulrich Hielscher 

points out time and time again how serious the 

consequences may be if customers use the wrong 

fl uids and mixtures of fl uids, or oils which are of 

inferior quality or do not comply with the specifi c 

operational requirements. “This may even cause the 

hydraulic system to fail.” That is why it is essential to 

select the right hydraulic fl uid. “Here it is the fi eld of 

application that decides - in other words, whether 

the system will be used for example for automotive 

engineering, in a press or smelting works and rolling 

mill; whether it is special-purpose equipment 

or a mobile work machine. The maximum operating 

pressure also plays a role, as does the ambient 

temperature and installation location.” No hydraulic 

fl uid is suitable for every application. These oils are 

just as varied as their possible uses. Many manufacturers 

of branded products clearly state what specifi 

cations an oil has to fulfi l for their equipment. “It 

is important to know in practical terms that the DIN 

standards for hydraulic fl uids only represent the 

minimum requirements for manufacturers and operators 

and are no longer suffi cient for most applications. 

For many plant and mechanical engineering 

companies the standard is merely the lowest 

level here”, explains Ulrich Hielscher. If an oil does 

not meet the manufacturer’s specifi cations, this 

may invalidate the warranty. If oils specifi ed with 

key performance data are approved by the manufacturer, 

the warranty may extend for two years, 

and if oils which are specifi cally named and have 

been fi eld-tested by the machine manufacturer are 

used, the warranty may even be for three years. 

Fluid under pressure 

When deciding which oil to use, it is a good idea to 

take a look at the technical data sheets provided by 

the oil supplier. They give the main characteristics 

of the oil, for example, the air release capability or 

ageing behaviour and its viscosity level. To play it 

safe, these data from the oil supplier and the manufacturer’s 

specifi cations should always be compared 

when selecting the type of oil. 

The viscosity does not characterise the quality of 

the hydraulic fl uid but indicates how it will behave 

at a certain reference temperature. In order to 

observe the limits on the use of a hydraulic fl uid, 

it is important to take account of the permitted 

minimum and maximum viscosity values given by 

the manufacturer of the hydro components. The 

viscosity of a hydraulic fl uid should not vary widely 

with fl uctuations in temperature or there will be 

a change in the volume fl ow rates at the throttle 

points. In terms of design it is also necessary to look 

at the critical range as on start-up, the oil in a machine 

should not be too viscous or there is the risk 

of it not reaching certain lubricating points quickly 

enough. However, once the operating temperature 

is achieved, the oil should not be too thin either or 

rubbing wear will not be adequately prevented. 

Hydraulic fl uids with a high viscosity index are 

mainly required for applications subject to wide 

fl uctuations in temperature, such as mobile work 

machines, vehicles or aircraft. 

ISSUE DECEMBER 2007

Maintenance costs money – 

repair costs more 

Hydraulic installations require precise lubrication 

if all components are to be properly controlled 

and to ensure smooth operation. In such systems 

large volumes fl ow through small spaces under 

high pressure. During this process tiny particles 

of dirt form a fi ne “grinding paste”, which causes 

wear through abrasion. Friction must be reduced 

between cylinders and lift rods. Most hydraulic 

components move on a very thin fi lm of oil, 

which cannot be seen with the naked eye. This 

guarantee smooth functioning of the machine. 

But only without friction when the oil is absolutely 

clean, something that in practice is virtually impossible 

– in Ulrich Hielscher’s experience. “Firstly, oil 

is always subject to ageing in service. Temperatures 

that are too high and too much air in the system 


will w cause it to oxidise. Secondly, water can get in as 

condensation, and abrasion on hose lines (elastomers) 

and pistons or cylinders does not fail to leave its 

mark.” Experience has shown that 75 percent of all 

hydraulic fl uids in hydraulic systems are not clean, 

with w increasing levels of soiling reducing effi ciency 

and a the service life of components. The result is unintentional 

stoppages along with high costs. 

This T is why the right oil treatment is a decisive 

factor. f Here Ulrich Hielscher refers HANSA-FLEX 

customers to the FLEXXPRESS Fluid Service, which 

off ers machine operators the option of putting the 

responsible task of oil treatment in the hands of capable 

specialists. They can quickly make an accurate 

and a informative analysis of the oil status for every 

machine and submit individual suggestions for optimisation. 

t 

Thanks to our cooperation with the oil 

laboratory WEARCHECK, which is s not linked to any 

manufacturer, the result of an oil l check is available 

within w 36 hours. This can then be used to draw up 

an a action plan, extending from simple fi ltration of 

the t oil using the partial fl ow method thod to a complete 

oil change. 

Buying oil is a matter r of trust 

But things do not just end with selection election of 

the right oil and its treatment. “Buying 

oil is a matter of trust”, emphasises ses Ulrich 

Hielscher in his training courses. rses. 

A responsible supplier documents ents 

his oil deliveries with a technical cal 

data sheet and also provides in- n- 

formation about his quality as- 

surance procedure between the e 

refi nery and oil storage facility. 

If an oil has not been stored 

properly and has already taken 

up water, this will of course immediately 

impair its properties, 

possibly leading to complete 

failure of the machine. “Experience 

has shown that even new 

oils are often delivered heavily 

soiled. “For this reason I can 

TRAINING CENTER 

only recommend”, comments Ulrich Hielscher, “decontaminating 

oil using a partial fl ow fi lter system 

before fi lling the installation.” This also forms part 

of responsible oil treatment! 

The HANSA-FLEX Fluid Service (Tel. 0800 77 12345) 

is the simplest route to eff ective oil treatment. It 

consists of specialist services ranging from help 

with “water in the oil” to a changeover to bio-oil. 

The FLEXXPRESS fl eet is being gradually fi tted out 

with the mobile equipment for the Fluid Service. 30 

vehicles currently have such equipment on board in 

order to help customers with analysis of their fl uids 

and conditioning using the partial fl ow method. 

These systems can also be hired by HANSA-FLEX 

customers from an equipment pool if they want to 

perform oil decontamination themselves. 


WILLMANN 

On 1 January 2006 HANSA-FLEX Hydraulik GmbH 

took over the shares of Willmann Steuerungstechnik 

GmbH. A change in management is now scheduled 

for the beginning of 2008. 

With the sale of Willmann Steuerungstechnik 

GmbH to HANSA-FLEX Hydraulik GmbH, Wolfgang 

Willmann has taken a strategic decision for the future, 

designed to ensure the continuity of his company 

and so safeguard service for customers on a 

long-term basis. 

A long-term approach was at issue here, particularly 

as regards hydraulic steel construction, a speciality 

of Willmann Steuerungstechnik. This sector 

had in recent years already been under the control 

of Stephan Kallage, who remains at the company in 

a management role. This means that the company 

22 

20 successful years in the hydraulics sector 

Change in management at Willmann 


will not have to do without his specialist knowledge, 

so safeguarding company operations in terms 

of ongoing and new projects. The chances of success 

for two forthcoming hydraulic steel construction 

projects look very promising at the moment. 

Wolfgang Willmann was anxious to maintain direct 

contact with customers as fast technical assistance 

and personal support remain the bywords of the 

company. At the special request of HANSA-FLEX 

Hydraulik GmbH he initially continued to act as 

managing director in particular to arrange for his 

successor at the company and to ensure a smooth 

handover. 

This has now taken place. The fate of Willmann 

Steuerungstechnik GmbH is now in the hands of 

Stephan Kallage and Martin Brinkmann. Stephan 

Kallage takes over as technical director, while Martin 

Brinkmann is in charge of commercial management. 

In the fi eld Eilt Poppen will be playing an important 

role in account management and customer 

acquisition, so rounding off the team at Willmann 

Steuerungstechnik GmbH. 

“Expertise in Hydraulics” – Willmann Steuerungstechnik 

is set to live up to this claim in future. This 

is the challenge taken on board by the new team. 

With the technical know-how and experience of all 

staff the company will continue to satisfy the expectations 

of its customers to their full satisfaction. 

ISSUE DECEMBER 2007

Just answer the question correctly and an iPod nano 8 GB could be yours! 

Mail your entries to ma@hansa-fl ex.com or post them 

to HANSA-FLEX Hydraulik GmbH, Marketing Department, 

Zum Panrepel 44, 28307 Bremen, Germany. Please include 

your name and address. Entry deadline: 23rd of January 

2008. Only one entry per participant. Any recourse to legal 

action and any liability shall be excluded to the extent 

permitted by law. The prize may not be paid out in cash. 

Read in the following issue... 

02/08 

Openings 

October 

HANSA-FLEX Sp. z.o.o. Ul. Kwiatkowskiego 1 37-450 Stalowa Wola Poland 

HANSA-FLEX Hidraulika d.o.o. Sarajevska 2 18000 Niš Serbia 

HANSA-FLEX Hydraulic Ltd. 135/2 Moo 7, Bann Krua Road 18240 Amphoe Chaloem Phra Kiat Thailand 

November 

HANSA-FLEX Hydraulic Co. Ltd. Unit 3.5/F., Far East Consortium Bui Hongkong Hongkong 

HANSA-FLEX Bulgaria Ltd. Kuklensko Schosse No.21 4004 Plovdiv Bulgaria 

HANSA-FLEX Hydraulik GmbH Havelstr. 12-14 24539 Neumünster Germany 

December 

HANSA-FLEX Hydraulik GmbH Am Surbach 10 35625 Hüttenberg-Rechtenbach Germany 


Anniversary 

iPod Nano, 8 GB (up to 2000 tracks), colour: black or 

silver; incl. earbud headphones, USB 2.0 cable, dock 

adapter, Software iTunes for Mac & Windows; requirements 

PC: USB 2.0, Windows XP Home or Professional 

Service Pack 2 (or newer), iTunes 7.4; requirements Mac: 

USB 2.0, MAC OS X 10.4.8 or newer; (actual product may 

diff er from displayed image) 

December 2007: HANSA-FLEX Elsterweda 10 years 

January 2008: HANSA-FLEX Barleben 10 years 

HANSA-FLEX Zwenkau 10 years 

XWORLD ADVENTURE 2008/2009 Preparations for the start in Bremen 

In conversation with … Regional manager Thorsten Hellmann 

Special vehicle construction Stokota off ers winning new concepts 

Training centre All oil is not the same 

Industrial hoses A new range for the sea water sector 

Oil service Improving machine availability, cutting costs 

FACTS & FIGURES | PREVIEW 

Win an iPod nano! 

After what time is the result of an oil 

sample by WEARCHECK available? 

A: 24 hrs 

B: 36 hrs 

C: 48 hrs 

Correct answer issue 10/07: 

B: Suak Nie, C. Seidel, Dortmund 

Facts & Figures 

Gesamt 

316 

165 

Preview 

Deutschland 

175 

91 

Copy deadline: 25th of January 2008 


23

HYDRAULIKPRESSE - HANSA-FLEX Hydraulics Canada Inc.

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