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TOOLMAKING

THE SUPREME DISCIPLINE

FLUSHING SYSTEMS

MORE CHOICEMORE VALUE

CUSTOMER MAGAZINE

DECEMBER 2019

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CONCEPT/DESIGN/REALISATIONLinkgroup AG, Zurichwww.linkgroup.ch

PHOTOSBen Huggler (cover, page 14)Iris Cook (pages 6–9)Shutterstock (page 13)SARC Architects/Tuomas Uusheimo(pages 17–18)

Issued quarterly.The reproduction of individual articles, in part or in full, is subject to approval from the editorial staff.

ON THE COVER

The moulds from the toolmaking depart-ment are used at the production facil- ities in Rapperswil-Jona (CH) and Pfullen- dorf (DE). Pictured here is a high-gloss polished mould used for manufacturing the Sigma01 actuator plate.

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6 BEHIND THE SCENESMOULDS WITH MILLI-METRE PRECISION FROM THE TOOLMAK-ING DEPARTMENT

14 COMPETENCESCALCULATING SANITARY NOISES

16 TIPS & TRICKSDESCALING GEBERIT AQUACLEAN

5 News

10 Customer event in Cape Town

13 Geberit Flushing Systems

18 Reference object in Helsinki

DEAR CUSTOMERS,WATCHMAKING IS A CRAFT THAT IS KNOWN FOR ITS PRECISION.

Similar levels of precision can be found in the in-house toolmaking department at Geberit. With outstanding technical skills and a keen eye, toolmakers create moulds for injection moulding and blow moulding machines. Accuracy is just as important in the Geberit workshops – and at every work step to boot, starting from the design data all the way through to honing and then assembling the individual components to form the finished tool.

Toolmaking is thus one of the most important success factors at Geberit. It is not only where all the know-how from product development comes together, but also a source of expertise in production itself as a developer and manufacturer of new moulds. The flawless moulds ensure the undisputed product quality that Geberit is known for.

This issue not only contains more information on the in-house toolmaking department, but also other exciting stories about Geberit and the product range.

I wish you an entertaining and informative read.

Mark SchurrManaging Director

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EDITORIALCONTENTS

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OKTOBERFEST@GEBERITFast becoming one of the most antici-pated events of the year. Geberit South-ern Africa held its second annual Okto-berfest. Industry partners were invited for an evening of festivities. The evening was aimed at showing appreciation for relationships and efforts that have as-sisted the Geberit team in South africa grow. The evening was filled with laughs and plentiful conversation. There was also a selection of craft beers as well as German-style cuisine. We look forward to seeing our partners again next year.

RETIREMENT VALERIE NOBELThe team at Geberit Southern Africa would like to bid a fond farewell to Valerie Nobel who will be retiring at the end of the year. Valerie has been a part of the Geberit team in Cape Town since its inception 20 years ago. Over the years, Valerie has become a key member of the logistics team and become an inspir- ation to the rest of the team in South Africa for her hard work and dedication. Valerie will officially become the first member of the team of Geberit Southern Africa to retire. The team at Geberit Southern Africa would like to wish Valerie all the best on her well-deserved break and thank her for her many years of service.

SHOWROOM UPGRADESThe showrooms at the Geberit offices in Cape Town and Johannesburg will be undergoing upgrades. These upgrades are necessary in order to showcase the new additions to our ranges. These addi-tions include the new Geberit myDay series, as well as upgrades to the Geberit Smyle range. If you would like to visit one of the Geberit showrooms, please feel free to contact the office located nearest to you. Our team members would be happy to assist you with a walk- through and answer any technical ques-tions you may have.

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NEWS

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TOOLMAKING AT GEBERIT

THE SUPREMEDISCIPLINE

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In order for Geberit to produce first-class plastic components and products, the corresponding injection moulds and blow moulds have to be of the very highest quality and precision. This is the job of the in-house toolmaking department.

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The machines in the production halls in Rapperswil- Jona (CH) are running at full steam. Tens of thousands of plastic parts are injection-moulded here every day. The story is the same at the plant in Pfullendorf (DE). Without highly automated production facilities with injection moulding and blow moulding machines, these volumes would not be possible – and certainly not in the precision and surface quality that Geberit strives for. What not many people know is that behind this outstanding quality are toolmakers that work at the very highest level.

HIGHLY CONCENTRATED AND WITH PINPOINT ACCURACYThe in-house toolmaking departments in Jona and Pfullendorf specialise in the production of moulds that are required in the injection moulding and blow moulding processes. At the two sites, a total of some 70 toolmakers, draughtsmen and other specialists go about their tasks in workshops equipped with state-of-the-art machines. It is immediately clear that qual-ity and precision are of huge importance here.

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A look inside the assembly area, where the tools are given their finishing touches.

TOOLMAKING = MOULD BUILDING

Pipe fittings, actuator plates and concealed cisterns – all of these products are made in injection moulding and blow moulding machines. The moulds found in these machines are produced by the toolmaking department (also known as mould building). In the injection mould-ing process, liquid plastic is injected into a mould at a pressure of up to 2,000 bar, where it then hardens be-fore the finished component can be taken out of the mould. Due to the high quality standards and the heavy loads they are subjected to, the moulds have to meet particularly strict requirements. For example, the machining and heat treatment of the wear-resistant special-grade steel mean that the tool is relatively robust. Perfect assembly of the individual components and a final inspection of the functions ensure that the liquid plastic then flows into the prefabricated mould as required and that there are no unexpected quality defects on the final product.

BEHIND THE SCENES

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A member of staff painstakingly inspects a compo-nent that has been milled from a block of steel by a computer-controlled machine before they can then combine this with the remaining components to make a complete mould. It’s clear to see that working by hand is still in demand here despite the high levels of automation. “A toolmaker works at a level of precision down to mere one thousandth of a millimetre. Such accuracy can only be achieved by well-trained staff,” explains Michael Zinser, Head of Toolmaking. Even the smallest deviation can mean that a mould is rendered useless. Days of work would then have gone to waste in such cases, not to mention the associated financial losses. As Michael Zinser explains: “A finished tool can cost several hundred thousand francs.”

FROM THE BLUEPRINT TO THE FINAL MOULDThe toolmaking department springs into action when moulds are worn out or damaged, or when Geberit launches a new product. In the event of new products, the production of a new mould starts when the prod-uct data is passed on by the development depart-ment. Using this already very precise data – consisting of 2-D drawings and 3-D data – the draughtsman builds the virtual mould on the computer using CAD software. This results in a detailed tool design. Even at this early stage, there is only a low fault tolerance

“Our moulds are highly complex, precise

one-off items.”

Michael Zinser Head of Toolmaking Geberit

“Constructing an injection moulding tool is like

in Formula 1 – one mistake and we won’t reach the

chequered flag.”

Michael Zinser Head of Toolmaking Geberit

as the design has to meet the requirements of the in-jection moulding or blow moulding machines exactly. Special attention is already paid here to the separ- ation of the two halves of the mould. Ventilation and temperature control of the mould are also already taken into account during this early phase.

Based on the design data, the machine programmers then write a CAM program for manufacturing the indi-vidual components. This program contains all relevant data from the design phase that the CNC machine needs, meaning it can then manufacture the cor- responding component step by step – ideally in a completely automatic process. Here, the steel plates from which the moulds are made are clamped in the machine and then processed using a range of meth-ods, including milling, eroding, turning and grinding. Milling and erosion are used particularly often, with the former ensuring rotation-symmetric preparation of easily accessible geometries and the latter used for sharp edges and openings. The components also un-dergo different heat treatment processes.

Once the individual components have been prefabri-cated, they are then finished, measured, examined and then assembled into a complete mould. “The as-sembly process is a particularly delicate job that re-quires a lot of experience and a steady hand,” explains Michael Zinser. “In order for the mould to remain in use for a long time, all the components must be perfectly coordinated with one another.”

FAST REACTION TIMESThe toolmaking department not only produces new moulds – they are also responsible for the maint- enance and repair of existing ones. Despite the robust materials used, it can happen that a mould can no longer be used as a result of wear or damage. Another benefit of having an in-house toolmaking department comes to the fore here. “External toolmakers are not able to react to unforeseen circumstances with the same level of flexibility as us,” explains Michael Zinser. “Once the production department notifies us of a re-pair, we can start immediately. This flexibility is a major advantage as downtimes at our production facilities should be kept to an absolute minimum.” Depending on the level of damage, the moulds are often back in operation the very next day.

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Coordination between manufacturing and assembly is important. The next steps are worked out together.

8 Know-how December 2019

BEHIND THE SCENES

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Three questions for Michael Zinser, Head of Toolmaking in Pfullendorf (DE) and Rapperswil-Jona (CH)

PRECISION IS THE TOP PRIORITY

What are the distinguishing features of toolmaking at Geberit?We have very well-trained, motivated and conscien-tious staff. They often have to work to tight dead-lines, yet always have to deliver perfect results. Pre-cision is the top priority. We are also very flexible. If a tool should give up the ghost during production, we switch things around and take care of the re- pairs immediately. In this way, we play our part in the punctual delivery of products to our customers.

Why is precision so important in toolmaking?We often only come in when a project is in the im- plementation phase. By this point, a lot of time and money has already been invested in the neces-sary tests and optimisations. Everybody involved wants the new products to be launched on the mar-ket as quickly as possible. However, each quality defect on our tools has direct consequences for the market launch and the product quality.

How long can a tool be used on average?A tool design that has been tested to the limit com-bined with the selection of the best steel for the job lays the foundation for a high-quality tool that causes only minimal follow-up costs across its entire service life and ensures high levels of avail- ability. If the tools are not damaged too heavily, they can remain in operation for decades. Every euro that is invested in the quality of the tool is then paid back with interest across its service life through the lower repair costs. We call this intel- ligent saving.

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A member of staff carefully puts together the two tool parts.

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Using an eyepiece, a member of staff checks whether the surface of the mould core is up to scratch.

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BEHIND THE SCENES

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MEET UP IN CAPE TOWN

AN EVENINGBENEATH THE STARSA cold, wet, Capetonian winter’s evening could not stop Geberit industry partners from enjoying night out on the town. Their bravery was rewarded by a wonderfully entertaining evening that was enjoyed by all.

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PARTNERSHIP

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Colourlab has brought people together and has helped create lasting memories.

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Think COLOUR and prepare yourself to be delighted and inspired.

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Cape Town based singer and guitarist, Liam Culbert, performs for corporate and private events in Cape Town and surrounds.

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Bruce Whitfield is a creative and engaging presenter who makes money matters understandable and accessible to listeners.

The event was hosted in the heart of Cape Town. A spacious rooftop studio called Colourlab, the venue is the brain child of creative genius, Petra Vonk. It boasts stunning views of the city and its surrounding attrac-tions. It is abuzz with vibrant colours and interesting pieces of art. Every square metre, a talking point. In the planning stages of the event, Petra and her team worked tirelessly to ensure the event was a success.

ATMOSPHERE TO ENJOY Guests were greeted with welcoming cocktails and were serenaded by one of Cape Town’s most promis-ing up-and-coming musical artists, Liam Culbert. The natural, resonating energy of the room allowed for a relaxing, fun atmosphere. Guests from all parts of the sanitaryware industry were mingling, laughing and exchanging stories from the year that has been. The balcony, which provided a breath-taking view of Table Mountain, was a hotspot for many of our guests, be-fore the cold set in, that is.

An emphasis was put on the gratitude and apprecia-tion that Geberit has for our industry partners. The evening happened to coincide with the anniversary of the opening of the Cape Town branch. The success of which would not have been possible without the help of our industry partners.

Giving in to the cocktail evening, the menu was chock-a-block with bite-sized portions of some delectable meals. This tapas style of serving meant guests were free to mingle and move as they would have liked. This created an electric atmosphere.

SPECIAL GUEST BRUCE WHITFIELDWe were lucky enough to secure one of South Africa’s foremost economic minds to deliver a key note speech to the group, Mr Bruce Whitfield. Mr Whitfield is a well-known, South African personality. He hosts a daily radio show, contributes articles to local news- papers and is a frequent guest on the local news circuit. Mr Whitfield engaged guests in the realities of the South African market. He laid bare that, yes, the South African economy is not in a great place at the moment. But stressed the importance of maintaining an open mind. “Never waste a good crisis,” was his mantra. He pointed out to our guests the importance of being opportunists and the benefits that could be gained by looking to solve the issues currently being experienced in the country.

A special thank you must go out to our partners within the industry. We thank you for your continued support and look forward to fostering these relationships throughout the years ahead.

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PARTNERSHIP

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Since 1905 when Geberit released its first cis- tern, an exposed wooden box, Geberit has been at the forefront of flushing technology. Over the years, Geberit has continuously improved on this design. This ultimately led to the creation of the concealed cistern.

GEBERIT FLUSHING SYSTEMS

MORE CHOICEMORE VALUE

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Geberit cisterns and actuator plates:

the standard for flush technology.

Geberit concealed cisterns have been designed to be functional in a variety of installation scenarios. Geberit offers cisterns that can be installed in brick or dry-wall-ing, for wall-hung or floor standing pans. Coupled with the wide selection of actuator plates, which share a name with the appropriate cistern, means that there is truly a Geberit solution for any application.

Geberit has recently introduced its latest concealed cistern advancement: The Geberit DuoFresh. The new odour extraction unit brings comfort and fresh air into the bathroom. Unpleasant odours are removed right where they develop and are purified by an efficient ceramic honeycomb filter. What’s more, a practical orientation light makes it easy for you to find your way to the toilet at night. The Geberit DuoFresh module can be combined with different Geberit actuator plates and can be retrofitted.

Geberit cisterns are designed to be long lasting and easy to use. Still, Geberit offers a ten-year warranty on its cisterns. Geberit also has a 25-year spare part guarantee, ensuring that spare parts should always be available should they be required.

Should you wish to view our wide range of products or acquire further information on Geberit products, you are most welcome to visit our offices in Cape Town, Durban and Johannesburg.

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PRODUCTS & SOLUTIONS

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Digital calculation models may be used to predict the extent to which sanitary noises spread in a new residential building. The programs required for this are already in use in some places. Geberit not only supports sanitary engineers and architects by providing the relevant data, but also practical advice.

For many years, Geberit has determined the sound levels of sanitary installations in its own building tech-nology and acoustics laboratory and had the results validated by an independent testing institute. Meas-uring results from hundreds of different installation situations and sanitary systems seen in solid con-struction projects are now available. Based on this data, which has been determined as part of very real-istic tests, the acoustics experts at Geberit can as-sess the sound propagation in building projects with a high degree of reliability – at least when it comes to

CALCULATING SANITARY NOISES VIA COMPUTER

“HOW LOUD IS IT GOING TO BE?”

sanitary noises. Given the increasing importance of computer-generated forecasts for installation noises, Geberit set up a new test facility in the Building Tech-nology and Acoustics Laboratory. This can be used for determining the data that is required for the digital calculation models.

THE RECEPTION PLATE METHODThe first standards for computer-based forecasting of sound propagation in solid structures have already been established, with calculation models for instal-

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COMPETENCES

Know-how December 2019

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“With EN 12354-5, uniform calculation models for installation noises are

available for the first time. This is a major step in the right direction.”

Oliver Wolff Head of Building Physics Geberit Group

installed but only half-height GIS sanitary module with the same fittings. The sometimes significant differ-ences can largely be attributed to the different system configuration and connection technology.

THE DIFFERENCE FROM THE REALISTIC EXPERIMENTTo now determine how much sound is transmitted from a certain sanitary installation to the building structure, the installation is measured acoustically in a test facility for reception plates. A facility like this has been built at the Building Technology and Acoustics Laboratory in Rapperswil-Jona (CH) according to the specifications laid out in the EN 15657 standard. This consists of three decoupled, homogeneous, 10-cm-thick concrete plates (one horizontal and two vertical). The plates are also decoupled from the floor and walls.

The installation elements and sanitary walls to be in-spected are professionally installed on and in front of these plates. The structure-borne sound that these elements transmit to the individual plates when in op-eration can then be determined. The results are used afterwards as input data for digital calculation models. “The sound propagation values that are forecast by these models sometimes differ significantly from the measuring results seen earlier when using the realistic test setup,” comments Oliver Wolff, Head of Building Physics at Geberit International. “The reasons for this are varied. Therefore, in complex building projects in particular it is important that the architects and sani-tary engineers not only rely on model calculations when planning the layout of the sanitary installations, but also on the expert knowledge of the manufacturer.”

lation noises now also available with the EN 12354-5 standard. These models work with input data that has been calculated using the reception plate method (EN 15657), which is explored in more detail below.

Each sanitary wall has its own acoustic characteris-tics. A correctly installed floor-to-ceiling Geberit Duofix installation system with elements for the cis-tern and washbasin that is connected to a floor drain-age system consisting of Silent-PP pipes, for example, has different acoustic characteristics to a correctly

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During this planning stage, it can be determined how much structure-borne sound will eventually be transmitted from the sanitary walls to the building structure and how loud the sanitary noise in neighbouring rooms will be.

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COMPETENCES

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1 Inlet for descaling agent

2 Continuous flow heater

3 Water pump

4 Water tank

5 Turning valve

6 Spray unit

GEBERIT AQUACLEAN

DESCALING MADE SIMPLE

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The descaling agent is flushed through all water-bearing parts (highlighted here in blue).

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TIPS & TRICKS

Know-how December 2019

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The Geberit descaling agent can be ordered conveniently. Please feel free to contact us.

USEFUL INFORMATION

– Descaling is required at least once a year.

– All water-bearing components are treated in the descaling programme.

– The Geberit AquaClean app is there to let the operator know when the next descal-ing is due.

– All Geberit AquaClean models can be used without the spray functionality dur-ing the descaling programme.

– The time required by the descaling pro-gramme varies depending on the model: Mera = max. 60 minutes, Sela = max. 40 minutes, Tuma = max. 30 minutes.

– In order to prevent damage to the device caused by aggressive media, it is recom-mended to only use Geberit AquaClean descaling agent.

– After filling with descaling agent, the des-caling procedure should not be cancelled as the agent would then be flushed out without being used.

Hard water is found in many places. Shower toilets contain pipes and parts whose functionality can be affected if operated with hard water for long periods. For this reason, Geberit shower toilets are equipped with an automatic descaling programme.

Lime – or calcium carbonate to give its chemical name – can be found in a range of different rocks and soils, where it is washed out by rainwater. In doing so, the calcium carbonate reacts with the carbon dioxide dissolved in the water and forms highly soluble cal-cium bicarbonate. The enriched water then reaches the consumer via the waterworks as drinking water. If the drinking water is heated in the shower toilet, the soluble calcium bicarbonate decays to form insoluble calcium carbonate – or limescale. This limescale set-tles on all surfaces that come into contact with water and results in malfunctions over time. If a layer of limescale builds up on heated parts – such as the heater in the shower toilet – the transfer of heat from the heater to the shower water is restricted. In the worst case, this can lead to faults on the heater.

AUTOMATIC DESCALING PROGRAMMEIn order to prevent damage to water-bearing com- ponents, the shower toilet has to be descaled regu-larly. For this reason, all Geberit AquaClean shower toilets are equipped with an automatic descaling pro-gramme. On all models, the control panel shows when descaling is necessary. After the descaling agent has been added by hand, the procedure can be started at the touch of a button. In the subsequent 30 to 60 min-utes, the descaling agent is fed through all water-bear-ing components such as the water tank, continuous flow heater and water pump. During the procedure, it reliably removes deposits from all components. Finally, the agent is flushed out together with the removed limescale. The descaling agent is safe for the environ-ment as the reaction of the agent with the limescale neutralises the acids contained within.

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TIPS & TRICKS

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NEW CHILDREN’S HOSPITAL, HELSINKI, FINLAND

STATE OF THE ART MEDICAL CARE IN COLOUR-FUL SURROUNDINGS

The New Children’s Hospital in Helsinki opened in autumn 2018. The qualified personnel, state-of-the-art equipment and friendly atmosphere ensure first- class medical care for the young patients.

NEW CHILDREN’S HOSPITAL

Building owner: New Children’s Hospital FoundationArchitecture: SARC ArchitectsCompleted: June 2018

GEBERIT KNOW-HOW

Duofix installation systemMapress and Mepla supply systemsIDO Seven D washbasinsIDO Seven D WCs

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The appearance of the facade panels changes depending on the angle they are looked at.

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Anything but drab and boring – the bright facade of the children’s hospital immediately catches the eye.

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REFERENCES

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Opened in autumn 2018, the children’s hospital has a wealth of child-friendly rooms and lots of colourful recreation spaces. The young patients enter a fantasy world stretching across eight storeys. The journey begins in the underground floor, which represents the seabed, and continues up into the forest before end-ing in outer space. Even from the outside, the new building is anything but a drab concrete block. The building’s facade, which is adorned with numerous colourful slat-like elements, looks like a never-ending rainbow.

STATE-OF-THE-ART INFRASTRUCTUREHelsinki’s New Children’s Hospital cost around 170 million euros to build, almost 40 million of which came from donations. The 140-bed hospital centralises the treatment of children from across Finland and abroad. Furthermore, the institution, which belongs to the Hel-

sinki University Hospital, specialises in the treatment of heart diseases and various cancers as well as organ transplants. The young patients, who range from new-born babies right through to adolescents, are looked after by a team of around 1,000 specialists and nurs-ing staff, who have the latest infrastructure and tech-nologies at their disposal as well as direct access to the Helsinki University Hospital’s research institutes.

The sanitary facilities at the hospital – which also feature Geberit products – are also impressive. The Duofix installation system is installed behind the wall, to which the high-quality washbasins and WCs from the Finnish brand IDO are attached.

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The recreation rooms have an inviting, relaxing atmosphere and take visitors and patients alike on a journey to another world.

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Geberit Southern Africa (Pty.) Ltd.6 Meadowview LaneMeadowview Business EstateLongmeadow, Linbro ParkZA-Johannesburg

Phone +27 11 444 50 70sales.za@geberit.com

www.geberit.co.za

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