Metal forming technology and welded assemblies for the automotive industry – from toolmaking to KTL-coated series parts
Brandl Industries SCS GmbH & Co. KG
Pfeffenhausen, DE · Kaplice, CZ · Sibiu, RONew on Amplifa
About Brandl Industries
Founded in 1970, Brandl Industries is a metal processing group with three locations in Germany, the Czech Republic and Romania. As a supplier to the automotive industry, it serves in particular the premium segment. The company produces stamped and formed parts through punching, bending and deep drawing, complex multi-stage components as well as welded assemblies and assembled components made from all common steel grades and aluminium alloys. Its value chain covers design (CATIA V5, simulation), in-house toolmaking for tools up to 50 t in weight, prototype construction, series production on 124 presses at three locations, joining technology with 32 welding robots and 54 spot welding machines, as well as surface finishing through pickling, trowalizing and cathodic dip painting (KTL). Production ranges from the smallest batch sizes on a manual loading station to series of several 100,000 units per year. The company headquarters is located in Pfeffenhausen (Bavaria), with plants in Kaplice (Czech Republic) and Sibiu (Romania).
- Site
- Pfeffenhausen
- Processes
- Stamped and formed parts (punching, bending, deep drawing), Drawn parts / multi-stage components (progressive and transfer dies), Prototype manufacturing of formed parts, Welded assemblies / welded components, Gas shielded welding (MIG, MAG, TIG), Arc fusion welding, Arc stud welding, Resistance press welding / resistance spot welding
- Materials
- Steel (all common steel grades), Aluminium alloys, Steel
- Certificates
- IATF 16949, ISO 9001:2015, ISO 14001:2015, ISO 50001:2019, ISO 9001, ISO 14001, ISO 50001
- Founded
- 1970
- Industries
- Automotive industry (premium segment)
- 01
Design & Development (CAD/CATIA V5, simulation)
- 02
Toolmaking (press, punching, drawing, welding, gauging and measuring fixtures)
- 03
Prototype construction
- 04
Series production (punching, bending, deep drawing)
- 05
Joining technology (welding, punch riveting, clinching)
- 06
Surface finishing (pickling, trowalizing, KTL)
- 07
Assembly of components
- 08
Quality inspection & project management
Materials & Processes
Steel
All common steel grades for stamped, formed and welded components, including crash-resistant and safety-relevant series parts.
Aluminium alloys
Aluminium for multi-part assemblies and formed parts in lightweight construction applications.
Locations
Pfeffenhausen
DEPlant I – Company headquarters, administration and strategic head office
- Materials
- Steel, aluminium
- Servo presses (400 t, 630 t, 800 t)
- Punching presses 80–400 t
- Eccentric press 2,000 t with 7 robot feed systems
- Design department (CATIA V5)
Kaplice
CZPlant II (BRAWE spol. s r.o.) – Press shop, welding technology, KTL surface finishing, assembly
- Lot size
- Small to large series
- Materials
- Steel, aluminium
- Pickling and KTL painting line (since 1999)
- Spot welding machines
- Welding robots
- CNC coordinate measuring machine
- Tool maintenance
Sibiu
ROPlant IV (S.C. BRANDL RO SRL) – Toolmaking, press shop, welded parts, series tools
- Part weight / size
- Tools up to 50 t
- Lot size
- Small to large series
- Materials
- Steel, aluminium
- Toolmaking on 2,000 sqm
- 50+ presses up to 800 t
- EDM center
- 3D laser cutting cells
- Robot welding systems
- CNC coordinate measuring machine
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Stamped and formed parts (punching, bending, deep drawing)Forming | – | – | – | smallest batch sizes (manual loading – several 100,000 units p.a. | Steel (all common steel grades), Aluminium alloys |
| Drawn parts / multi-stage components (progressive and transfer dies)Forming | – | – | – | – | Steel, Aluminium |
| Prototype manufacturing of formed partsForming | – | – | – | – | Steel, Aluminium alloys |
| Welded assemblies / welded componentsJoining | – | – | – | – | Steel, Aluminium |
| Gas shielded welding (MIG, MAG, TIG)Joining | – | – | – | – | – |
| Arc fusion weldingJoining | – | – | – | – | – |
| Arc stud weldingJoining | – | – | – | – | – |
| Resistance press welding / resistance spot weldingJoining | – | – | – | – | – |
| Projection weldingJoining | – | – | – | – | – |
| Punch rivetingJoining | – | – | – | – | Steel, Aluminium |
| ClinchingJoining | – | – | – | – | Steel, Aluminium |
| Laser welding (laser welding cells)Joining | – | – | – | – | – |
| Assembly of assemblies / assembled componentsAssembly | – | – | – | – | – |
| KTL coating (cathodic dip painting)Surface | – | – | – | – | – |
| PicklingSurface | – | – | – | – | – |
| TrowalizingSurface | – | – | – | – | – |
| Toolmaking (press, punching and drawing dies, progressive and transfer dies)Engineering | – | – | up to 50 t total weight | – | – |
| Manufacture of welding, gauging and measuring fixturesEngineering | – | – | – | – | – |
| Design/Development of tools and fixtures (CAD/CAM, CATIA V5, simulation)Engineering | – | – | – | – | – |
| Series and prototype toolmakingEngineering | – | – | – | – | – |
| Cutting/Laser cutting (2D/3D laser cutting cells)Machining | – | – | – | – | Sheet/steel, Aluminium |
| Milling (CNC, 3-axis/5-axis)Machining | – | – | – | – | – |
| Wire EDMMachining | – | – | – | – | – |
| Joining quality testing (weld spot testing, ultrasonic analyses, micrograph examinations)Testing | – | – | – | – | – |
| In-process quality assurance / CNC-supported metrology (coordinate measuring machine)Testing | – | – | – | – | – |
| Sheet metal processingForming | – | – | – | – | Steel, Aluminium |
20 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Presses (total, three locations) | – | 124 | – | – | – |
| Servo press | – | – | – | – | – |
| Servo press 400 t press force | – | 1 | – | – | – |
| Servo press 630 t press force | – | 1 | – | – | – |
| Servo press 800 t press force | – | – | – | – | – |
| Punching press 80 t to 400 t press force | – | – | – | – | – |
| Eccentric press 2,000 t with fully automated transfer operation (7 robot feed systems) | – | 1 | – | – | – |
| Milling machines (3-axis / 5-axis CNC) | – | 31 | – | – | – |
| Wire EDM machine | – | 8 | – | – | – |
| Welding robot | – | 32 | – | – | – |
| Spot welding machine | – | 54 | – | – | – |
| Laser cutting cell (2D/3D) | – | 3 | – | – | – |
| Laser welding cell | – | – | – | – | – |
| Pickling and KTL painting line | – | 1 | – | 1999 | Kaplice (Czech Republic) |
| CNC coordinate measuring machine | – | – | – | – | Kaplice; Sibiu |
| 3D laser cutting cell | – | – | – | – | Sibiu (Romania) |
| Robot welding system | – | – | – | – | Sibiu (Romania) |
| Press shop equipment (small to large, up to 800 t) | – | 50+ | – | – | Sibiu (Romania) |
| EDM center | – | – | – | – | Sibiu (Romania) |
| Large hydraulic presses | – | – | – | – | – |
Additional services
Quality & Certification
Production is accompanied by in-process quality assurance with CNC coordinate measuring technology as well as weld spot testing, ultrasonic analyses and micrograph examinations. The sites are certified to IATF 16949 and ISO 9001 (TÜV SÜD).
| Evidence | Pfeffenhausen | Kaplice | Sibiu |
|---|---|---|---|
| IATF 16949 | |||
| ISO 9001 | |||
| ISO 14001 | |||
| ISO 50001 |
History
- 1970
Foundation of 'Herbert Brandl Maschinenbau' by Herbert Brandl; initial orders in design and metalworking
- 1978
Construction of the first hall on Rottenburgerstraße, Pfeffenhausen; focus on tool manufacturing
- 1993
First foreign location: BRAWE in Kaplice, Czech Republic
- 1999
Commissioning of an in-house KTL painting line in the Czech Republic
- 2000
Opening of the Sibiu production site, Romania (Brandl-RO)
- 2001
Annual revenue exceeds €30 million for the first time
- 2010
40th anniversary; more than 1,000 employees worldwide
- 2014
Renaming to Brandl Maschinenbau GmbH & Co. KG; Andrea Brandl-Luckner acquires majority shares
- 2015
Record revenue: more than €75 million with series parts; launch of 'Brandl 2.0'
- 2017
Expansion of site competencies: Pfeffenhausen headquarters, Kaplice KTL, Sibiu welded parts/series tools
- 2018
New unified corporate identity as Brandl Industries