Written by Editors EUROGUSS 365
It all started with the construction of spray heads. Today, Gerlieva supplies complete spray systems for die casting systems, which are developed in close consultation with the customer and manufactured in-house with a depth of up to 95 percent.
“The combination of spraying technology with mechanical engineering was the decisive moment in our development,” recalls Armin Linbrunner, second-generation Managing Director.
This principle - everything from a single source, nothing off the shelf - runs through all projects. Instead of using standard components, Gerlieva produces form-related spray heads that are designed as specifically as the customers' die-cast parts themselves. The advantage: reduced cycle times, a longer service life for the molds and low-maintenance operation.
“The customer can use a spray head specifically designed for the die-cast part with process reliability and does not have to repeatedly check settings or, for example, the alignment and arrangement of nozzles as with a standard spray head,” explains Marc Linbrunner, Head of Mechanical Production and designated successor in the company management.
The lack of a supplier structure for special machine construction in southern Germany forced Gerlieva to manufacture in-house at an early stage. Today, this has become a strategic advantage. If you manufacture almost every part yourself, you can also respond to customer requests at short notice, make adjustments to ongoing projects and are independent of fragile supply chains. This self-sufficiency has proven to be a strength, especially in times of crisis. And, of course, the environment is also relieved because numerous transportation trips are eliminated.
Furthermore, this depth is not just a question of parts availability, but also of attitude: if you produce everything yourself, you know every detail. Customers also notice this when a system does exactly what it is supposed to do after months of continuous operation - without deviation, without readjustment.
At Gerlieva, “customer-specific” means that 3D data, mould geometries and machine parameters are analyzed together with the customer during the design phase.
“In some cases, we modify our control system and the spraying program during the final phase of the project - an approach that is part of our close customer relationship,” explains Oliver Fösel, Head of Coordination Management and Quality Management.
The fact that Gerlieva also develops and integrates the control technology itself makes this close cooperation possible. Optimization does not end with commissioning. Customer training, predictive maintenance and data analysis for process improvement are part of the fixed scope of services.
One example of this is the handling of maintenance and cleaning: spray heads must be regularly rinsed and tested in order to function properly. Gerlieva has developed a special system that automates these processes - with hot water, cleaning agents and a subsequent leak test. This takes no longer than a lunch break and gives the staff time for other tasks. In practice, this means less downtime, less waste and more time for the essentials.
In an industry where components and requirements change in step with model changes, adaptability is crucial. Gerlieva meets this change with flexibility - both technically and organizationally. Today, spray systems are not only designed for aluminum, but also for magnesium or special alloys. The requirements for dosing, cooling and spraying direction change with each material.
When the topic of giga-casting is discussed in the die casting industry today, superlatives are bandied about: huge castings, presses with enormous clamping force, complex process integration. Gerlieva is following this trend with interest.
“Our spray technology solutions are designed for machines with a clamping force of up to around 6,000 tons - that covers the majority of industrial die casting applications in the demanding but still conventional sector,” says Marc Linbrunner.
But the developments in giga-casting remain in view: If the market continues to develop in this direction and customer demand increases, Gerlieva is ready to become more involved here. Because here, too, you should never say never.
Back in the early 2000s, Gerlieva was commissioned by one of the largest US foundries for its first mold-related systems. The project became a milestone: not only technically, but also in terms of international partnerships. The decision to rely on technology from Heitersheim and provide local support from partners was later applied many times over. This was the beginning of the principle that still applies today: engineering from Heitersheim, combined with local support from international partners.
Today, Gerlieva works in many international foundries, but deliberately remains anchored in the SME sector.
“Especially in turbulent times, it is an advantage to be able to make decisions quickly, flexibly and at eye level with the customer,” emphasizes Armin Linbrunner.
“Our flat hierarchies help us not only to keep pace with technological developments, but also to help shape them.”
Spraying technology is a difficult process: release agent must be applied with millimeter precision, at a precisely defined density, temperature and direction. Minor deviations mean form errors, downtime and rejects. Gerlieva meets this complexity with a demand for robustness and durability. The combination of user-friendly technology and well thought-out service is also reflected in retrofit offers, with which existing systems can be upgraded.
With Marc Linbrunner, the next generation is in charge. And he is providing new impetus without betraying the company's DNA.
“Our strength has never been size, but proximity - to the product, to the process and to the customer,” says Marc Linbrunner.
"We are passing this on. We want to continue on the family course and at the same time actively shape change."
One sentence sums up the company's philosophy: “The whole is more than the sum of its parts.” Machines, people, processes - at Gerlieva, everything is interwoven. Anyone who understands this also understands why more is created here than just spray heads.
