Series production at EMKA
Manufacturing expertise from a single source
Thanks to our wide range of services, we are able to meet our customers’ individual requirements, from the development stage right through to the series production of a product. Controlled quality standards in accordance with DIN EN ISO 9001:2015 and a continuous improvement process guarantee a very high standard of quality. Highly qualified, long-serving employees represent comprehensive expertise.
Place your trust in our process reliability and our many years of experience in the manufacturing sector. We manufacture for the machinery and automotive industries, the electrical and telecommunications sectors, and the HVAC industry. We export to Europe, Asia and the USA. Our products are developed, manufactured, finished and assembled at twelve production sites in Germany, France, England, Spain, Bosnia, Serbia, China and India.
EMKA worldwide
Zinc die-casting
▪ Production in Germany, Bosnia and Herzegovina, India, Hungary and Indonesia
▪ 54 machines
▪ Machine manufacturers: Frech and Agrati
▪ Clamping forces: 20–220 tonnes
▪ Max. mould clamping area: 500 x 500 mm
▪ Part weights: 1 - 2,000 g
▪ Zinc alloys:
Z410 to DIN 1743, Z430 to DIN 1743, others on request
▪ 3 automated special-purpose machines for thread production
Plastic injection moulding
- Manufactured in Germany, Bosnia and Herzegovina, India and Indonesia
- 69 machines, including two 2K machines
- Machine manufacturers: Arburg, Engel, Demag
- Clamping forces: 20–500 t
- Max. mould clamping area: 720 x 720 mm
- Part weights: 1 – 1,200 g
- Granulate types:
- Thermoplastics such as PA/ PC/ PE /PS /POM /ABS /TPE /TPU
- Additives/properties such as glass fibre/carbon fibre/fire protection/rubbery to high-strength/transparent/chrome-plating compatible/others on request
- Closed material cycle, automated material processing, material feeding and part removal
Aluminium die-casting
- Manufactured in Germany
- Additionally certified to ISO 50001:2011
- 3 melting furnaces (2 tilting furnaces and 1 shaft furnace)
- Aluminium alloys: Al 226, Al 239, Sf 36, others on request
- Fully automatic robotic removal with deburring press
- In-house water treatment
- 9 machines
- Machine manufacturers: Frech, Bühler, Italpresse
- Clamping forces: 220 – 1,250 t
- Max. mould clamping area: 1,500 x 1,500 mm
- Part weight: 50 - 12,500 g
Aluminium forging and friction welding
- 1 forging machine
- Machine manufacturer: Weingarten
- Pressing force: 800 t
- Part weight: up to 4,000 g
- Forging alloys:
- AlMgSi0.5 / AlMgSi1, others on request
- AlMgSi0.5 / AlMgSi1, others on request
- 1 machine for friction welding
- Machine manufacturer: Kuka
- Pressing force: up to 20 t
- Diameter: up to Ø 90 mm
Precision casting of steel and stainless steel
- Manufactured in Serbia
- Part weight: 5 g – 3,000 g
- Component lengths: up to 250 mm
- Steel and stainless steel in various grades and alloys
- Tolerances in accordance with VDG P690 D2
- Surface finish up to N8 (Rz = 16 – 25 μm) possible without reworking
Profile extrusion
- Manufactured in Spain and England
- Plant in Spain additionally certified to ISO 14001:2015 and IATF 16949:2016
- 7 production lines for EPDM
- 2 lines for PVC
- 1 line for TPE
- 5 injection moulding machines (50–100 t) for the production of moulded corners
- Machine manufacturers: Gerlach, Itaigum
- Materials: EPDM, NBR, PVC, TPE
- Sealing profiles with and without metal reinforcement as mono and bi-profiles
- Manufacture of rings and frames as well as cut-to-length profiles
- Profiles with release coating, flock and adhesive tapes
Punching, bending and forming technology
- Manufactured in Germany and Bosnia and Herzegovina
- 46 machines
- Machine manufacturers: Andritz Kaiser, Haulick Roos, Edelhoff, Leinhass, Exner, Berninghaus, Walter, BBT, Post, Streicher, Burger
- Pressing forces: 15 – 2500 kN
- Material thicknesses: 0.5 – 4 mm
- Material widths: up to 300 mm
- Materials: Steel / stainless steel, aluminium, brass, copper
Machining
- Manufactured in Germany, Bosnia and Herzegovina, and China
- 3 rotary indexing tables
- 4 cam-controlled single-spindle / automatic lathes
- 15 CNC single-spindle / automatic lathes
- Machine manufacturers: Pfiffner, Index, Traub, Ergomat
- Turned part diameter: Ø 2 – Ø 65 mm
- Turned part length: 5 – 300 mm from bar stock
- Materials: Plastic, zinc, aluminium, steel, stainless steel, non-ferrous metals
- 4-axis machining
- Simultaneous machining with up to 16 tools
Post-processing / CNC
- Manufactured in Germany, Bosnia and Herzegovina, and China
- 34 CNC machining centres, 3–4 axes
- 23 lathes
- 9 grinding machines
- 14 Drilling machines
- 8 Threading machines
- 6 belt sanders
- 4 Milling machines
- 2 lathes
- Materials: Steel, stainless steel, non-ferrous metals, aluminium, zinc, plastic
Assembly
- In-house assembly in Germany and Bosnia
- Assembly work ranging from very small quantities on flexible assembly stations to the set-up of customised assembly lines for complex large-scale production assemblies
- Packaging scope in accordance with customer requirements
Product examples: EMKA Production
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