Mawick | Injection moulding quality made in Germany

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Mawick | We mould your ideas into plastic

Left

Chief executive Klaus Mawick and the

management team

Right

Conference room in the administrative building

Company site at Werl-Sönnern in the immediate vicinity of the A1, A2, A44 and A445 motorway interchange

For over fifty years, we have provided our customers with a full service in plastic injectionand blow moulding.

Since 1958, the Mawick name has stood for top quality inplastic injection moulding. Having started with garden andcamping accessories, we have continually expanded ourproduct range. In 1971, came a milestone in the Mawick success story: the development and productionof the first car battery box made of polypropylene. The associated battery lids have for a long time been one ofour company's core products.

Today, our large portfolio demonstrates our broad rangeof services and flexibility. It includes different products forthe automotive, electrical engineering and children's vehicle industries, as well as the household, the gardenand the agricultural sector.

8,000 tonnes of raw materials per year in 200 compositions of material and colour - the methods usedare as diverse as the products themselves. From high-volume plastics from the polyolefin range all the way tohigh-performance synthetics such as highly heat resistantthermoplastics - we are able to fullfill our customers'

every wish. We obtain the raw materials from major-name manufacturers so that we are able to ensure consistent high quality in combination with the requiredproperties of the raw materials used.

Our focus is on the customer. Each of our 280 employees is totally dedicated to fulfilling our customers'wishes and expectations and works hard to that end everyday at our site in Werl. In order to guarantee fast and flexible order processing, we work in a three-shift pattern,seven days a week, in many areas of production.

We mould your ideas into plastic! We provide a fullservice from a single source: from the idea all the way to delivering the final product. Design, tool making, production and logistics are all under one roof at Mawick- saving you time and money!

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CAD/CAM design | From draft to perfect product

Left

Computer simulation, filling trial

Right

3D product portrayalon the screen

Complex, large products inall their shapely, aestheticbeauty

From development to tool design, all the way to mass production – Mawick is your expert partner

Whether initial idea or finished parts design – atevery stage of the development process our design specialists are here to assist. Take advantage of our experienced employees' and their in-depth know-how.As a reliable partner, we will give you professional adviceand ensure precise implementation of your ideas. Yourpoint of contact with us remains the same throughoutthe entire project, thus guaranteeing a direct channel ofcommunication.

We develop and optimise the desired product incollaboration with our clients. In doing so, we placegreat importance on top product quality, without losingsight of the commercial aspects. Already during the initialbrainstorming phase, we have our eye on the entire production process. During the planning of the project,for instance, we take full account from the outset of yourideal end product: from design and tool development allthe way to the choice of the right plastic.

The design and tool-making departments work upoptimum solutions for you. The physical proximity ofthe two departments ensures a speedy process. Fast decisions and flexible adaptation are guaranteed.

The software we use in the design department is Unigraphics/IDEAS-NX and via interfaces we are able to work with all popular standard formats. No matterwhat stage of development you are at, when you cometo us, we will gear ourselves flexibly to you and yourproduct.

• All popular data formats can be read and processed

• The design department is equipped with highly modern CAD/CAM computers and Unigraphics/IDEAS-NX 3D-workstations

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Tool making | Quality down to the last detail

Left

Looking into acomplex tool

Middle

Partial view of thetool-making hall

Right

Manual precisionwork on the toolfor optical parts

Almost limitless productionoptions in terms of shape,colour, surface and components

Products with insert/assembly parts

Our tool-making know-how guarantees top precision of fit and perfectly accurate details in mass production

Our tool shop – a perfect product needs a perfect tool.Once the design is finished, we produce the optimum toolbased on the production department's specifications andenvisioning the end product. We proceed here with special care and precision.

Working on a multi-shift pattern in an area of 2,000square metres equipped with leading-edge high-perfor-mance mill centres and eroding machines, our employeesdeliver on-time manufacturing of precisely fitting tools andappliances. Where necessary they are assisted by externalpartners, with whom we have worked together successfully for many years. In this way we are able toreact to changes and complex requirements and complete extensive projects reliably within the planned timeframe.

Tool maintenance and servicing takes place immediatelyafter mass production. A proven team from our tool shopis responsible for the systematic maintenance, upkeep andcareful storage of the tools. They are in effect our in-house'tool inspectors'.

As a result of this continual care, the tools’ lifespan is extremely long. Our adjoining tool warehouse guaranteesyour tools' fast, immediate availability. They are thus readyfor production at all times and can be used again and againwithout delay.

The great variety of end products made is reflected in themany different tools: we currently have around 1,500 toolsin storage, made of steel or aluminium and weighing between 100 kilograms and 15 tonnes.

• Die-sinking machines• Wire-eroding machines• High-performance mill centres• CNC milling machines• Sanders• Lathes• Die-spotting presses

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Plastic injection moulding | Perfection again and again

At the core of our operations at Mawick are the injection-moulding systems. Around 50 machines with aclosing force of between 50 and 1,500 tonnes are availablefor your products. We have multiple units of almost allmachine sizes, enabling us to react quickly and flexibly tocustomer requests. Our machines are in use seven days aweek.

We produce around 70 million products annually.Their individual weights vary from 1 gram to 6 kilograms.In order to be able to offer this wide range, we use a multitude of methods.

Injection mouldingSingle and multi-component injection moulding, gas injection moulding and injection embossing are possible,as are insert moulding and heat-sealing.

Blow mouldingSupplementing this, two blow-moulding machines areavailable, which can make blow-moulded items with a volume of up to a maximum of 120 litres.

After production, we also take care of the best possiblefinish of your plastic products: we assemble and heat-seal on site and can paint, print, hot-stamp or metallise.

From individual products to entire assemblies - using certified production processes, we ensure top quality

Quality control guarantees customer satisfaction. At Mawick the same therefore applies to both, injection andblow moulding: during production the quality of the itemsis constantly monitored. Using QDE stations within every machine group, the quality of the finished products areregularly checked. For this we use the Quipsy's CAQ system, via which all captured data gets stored and archived.

However, it is not just the machines at Mawick that ensuretop quality, it is above all the people. All employees playtheir part here and take our key principle in relation to mistakes to heart: prevention is better than cure.

• Around 50 injection-moulding machines with a closing force of 50 to 1,500 tonnes

• Blow-moulded items with a volume of up to 120 litres

• Fusing of plastic parts using heating element,ultrasonic and friction bonding

• Product finishing by painting or metallising

Left

Quality assurance: digitally and by hand

Middle

Blow moulding: opened tool with

material hose

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Completely automated production area

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Fully assembled products seen in detail

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Assembly, storage, delivery | Flexible, reliable, on time

Left

Final assembly by hand

Right

High-rack storagewith units ready

to ship

Handling and processing: fast, reliable, efficient and monitored

We pack and deliver the products as requested by our customers – throughout Germany and worldwide

From individual parts to finished product: on request, we will not only supply the items injection-moulded by us, but we can also take care of componentand final assembly. In our warehouse, with space for12,000 pallets, your finished products are safely storeduntil needed.

Packing, storage and delivery - before your goodsleave our warehouse, you agree with us how and wherethey are to go. After final assembly we can, if you wish,go straight to using your sales packaging and labels forpacking the goods.

When it comes to shipping, we gear ourselves wholly toyour needs: in consultation with the client just-in-timedelivery can be set up. Be it to you at your factory orstraight to the end customer, whether around the corner or in Australia - with our highly experienced logistics partners we can deliver your products all overthe world. Thanks to the spacious layout of our loadingarea, we guarantee short stops for the trucks and rapidhandling.

Full service from a single source: the long-establishedcollaboration with our customers, for some of whom wehave been producing for more than 40 years, shows thatthis concept works. From the initial sketches all the wayto the final, assembled product, we work hand-in-handbased on your vision. For smaller batch sizes, we offertailor-made solutions too.

We look forward to moulding your ideas into plastic.

• Order documentation usinga modern PPS system

• Individual picking, customer-focussed storage and punctual shipping

• Global delivery service

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Josef MawickKunststoff-Spritzgusswerk GmbH & Co. KG

Pröbstinger Weg 3 · 59457 Werl-SönnernPhone +49 29 22-88 50Fax +49 29 22-88 51 00E-Mail info@mawick-online.dewww.mawick.eu

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Mawick products go almost all over the world -our business partners' worldwide production sites call for precise delivery to locations around the globe.

Mawick | Injection moulding quality made in Germany