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Series production at EMKA

Production expertise from one source

Due to our wide range of services we are able to meet individual customer requirements from the development to the series production of a product. Controlled standards according to ISO 9001: 2008 and a continuous improvement process guarantee a very high quality level. Highly-qualifi ed long-standing employees stand for comprehensive know-how. Rely on our process stability and our many years of experience in the fi eld of manufacturing. We manufacture for the machine building and automotive, electrical and telecommunications industry as well as for the HVAC sector. We export to Europe, Asia and the US.

EMKA worldwide

Zinc die casting

Number of machines:
42 in total

  • 16 in Wuppertal
  • 21 in Bosnia
  • 5 in France

Clamping force:

  • 20 - 200 t in Wuppertal
  • 20 - 315 t in Bosnia
  • 20 - 80 t in France

Maximum mould clamping area:
900 x 550 mm

Parts weights:
3 - 3000 g

Zinc alloys:

  • Z410 according to DIN1743
  • Z430 according to DIN1743
  • others on request

Machine manufacturer:
Frech

Additional information:
3 automated special machines for production of threads

Plastic injection moulding

Number of machines:
69 in total
Bosnia: 21 in plant 1 - 31 in plant 2

Bosnia plant 1:

  • 2 x 2K (630t i 370t)
  • 1 x 2K machine 720S

Velbert:

  • 16 x 1K machine
  • 1 x 2K machine 470S

Clamping force:

  • 30 - 150 t in Velbert
  • 25 - 650 t in Bosnia

Maximum mould clamping area:
1,100 x 600 mm

Parts weights:
3 - 3,000 g

Granular types:

  • Thermoplastic / PA 6 / PA 6 V0 / PA 6 GF / transparent, rubbery to high strength and chrome platable,
  • others on request
     

Machine manufacturer:
Arburg

Additional information:
Closed material loop, automated material preparation and feeding and parts removal

Aluminium die casting

Number of machines:

  • 9 die casting machines
  • 10 machining centres

Parts weights:
from 5 g up to 8 kg part weight

Stainless steel precision casting

Number of machines:
4

Part weight:
0.5 - 10,000 g

Materials:

  • Steel and stainless steel in all common qualities
  • Special alloys

Machine manufacturer:

  • Pilar USA
  • Eling Serbia

Additional information:
Surface treatments: electrolytic polishing; rough, mirror polished, brushed, galvanized and coated surfaces.

Punching, bending and metal working

Number of machines:
46 in total

  • 20 in Velbert
    7 automatic punching presses / special machines / 8 finishing presses
  • 25 in Bosnia
    2 automatic punch presses / 17 eccentric presses / 6 hydraulic presses
  • 1 in France

    Pressing force:
    80 - 250 t

    Material thicknesses:
    1 - 5 mm

    Materials:
    Steel / stainless steel / aluminium / brass

    Machine manufacturer:

    • Edelhoff
    • Kaiser
    • Leinhaas
    • Exner
    • Burger
    • Walter
    • Ruhrmann

    Extruding

    Number of lines:

    • 7 lines for EPDM
    • 4 in Spain / 3 in England
    • 2 lines for PVC in Spain
    • 1 line for TPE
    • 5 injection moulding machines (50 - 100 t) for the production of corners

    Materials:

    • EPDM
    • NBR
    • PVC
    • TPE

    Machine manufacturer:

    • Gerlach
    • Itaigum

    Additional information:
    Sealing profiles with and without metal reinforcement, as mono and bi profiles. Production of rings and frames, as well as ready-made lengths. Profiles with bonded coatings, flock and adhesive tapes

    Machining

    Number of machines:

    • 3 rotary indexing tables
    • 4 cam-controlled single-spindles / automatic lathes
    • 13 CNC single-spindle automatic lathes

    Series production:

    • 100 - 100,000 pieces

    Turning part diameter:

    • Ø 2 - Ø 65 mm

    Turning part length:

    • 5 - 300 mm from the bar

    Materials:

    • plastic
    • zinc
    • aluminium
    • steel
    • stainless steel
    • non-ferrous metals

    Machine manufacturer:

    • Pfiffner
    • Index
    • Traub
    • Ergomat

    Additional information:
    4 axis machining, driven tools, multi-edge hammering, simultaneous machining with up to 16 tools, dimensional accuracy up to H7 (0.02 mm) without reworking, parting of without slugs

    Post-processing / CNC

    Number of machines:
    Wuppertal

    • 3 CNC machining centres, 3 - 4 axes
    • various conventional drilling machines
    • lathes
    • milling machines
    • grinding machines

    Bosnia Plant 1:

    • 14 drilling machines
    • 8 threading machines
    • 6 belt grinders
    • 2 milling machines
    • 2 lathes

    Series production:
    5 - 10,000 pieces

    Materials:

    • steel
    • stainless steel
    • non-ferrous metals
    • aluminium
    • zinc
    • plastic

    Machine manufacturer:

    • Haas
    • Ixion
    • Hestika etc.

    Aluminium forging

    Part weight:
    up to 2.5 kg

    Pressing force:

    max. 800 t   

    Friction welding

    Diameter:
    up to 90 mm

    Welding force:
    up to 20 t

    Total length of the parts:
    up to 1,600 mm

    Seal foaming

    Number of machines: 3

    • 2 in Velbert
    • 1 in Bosnia

    Mixing, dosing and CNC-controlled robots

    Protection classes:
    up to IP 69K

    Machine manufacturer:

    • Rampf
    • Sonderhoff
    • Kian Shi

    Additional information:
    Fully automatic application of captive seals

    Finishing and assembly

    Assembly work on individual parts and complex assemblies

    Finishing solutions:

    • Grinding
    • Sandblasting
    • Polishing
    • Drilling
    • Thread cutting
    • Machining on rotating parts
    • Imprinting by tamponading

    All packaging requirements are fulfilled as a matter of course. We are also happy to mark the products according to the customer's wishes - e.g. with a logo print.

    Brochure Mould Making 2020

    EMKA Mould Making
    EMKA Bosnia d.o.o

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    Brochure EMKA Precision casting 2021

    EMKA Precision casting
    Production competence from one source

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    Version 2017
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    Brochure EMKA Aluminium 2021

    EMKA Aluminium
    Production competence from one source

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    Catalogue Sealing technology 2020

    SEALING TECHNOLOGY
    MADE TO MEASURE
    Profiles and Frames from
    In-House Production

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