GEA Refrigeration Technologies
GEA Refrigeration Technologies
Factory Tour: Production of GEA Bock compressors in Frickenhausen
engineering for a better world
2
In Frickenhausen, GEA Bock compressors and condensing units for stationary and mobile refrigeration as well as for air conditioning are produced.
We offer the right compres-sor for refrigeration and air conditioning in all com-mercial, industrial, rail, bus and transport sectors. GEA Bock has been a com-pany of GEA Group Aktieng-esellschaft since 2011 and is part of the GEA Refrigeration Technologies segment. The Frickenhausen site is divid-ed into Administration, Training Center and Production. Prod-uct-related training courses take place in the Training Center. Thousands of GEA Bock com-pressors are manufactured annually in a production and warehousing facility with a total surface area of 8,600 m².
GEA Refrigeration Technologies
Administration
Production
Training Center
3
FK vehicle compressors Lightweight, compact, robust and efficient vehicle compressors for mobile air conditioning and refrig-eration systems.
Classic applications: Bus air condi-tioning, rail air conditioning, trans-port refrigeration.
F open-type compressors Open type compressors for exter-nal drive (via V-belt or coupling). Classic applications: Marine sector (e.g. provision cooling, ship air con-ditioning).
Semi-hermetic compressors Suction gas-cooled semi-hermetic HG compressors and air-cooled semi-hermetic HA compressors. Also available as semi-hermetic condensing units (e.g. Plusbox out-door complete condensing unit). Classic applications: Supermarket refrigeration, commercial air condi-tioning, building technology.
Product range of GEA Bock compressors
4
1932
1937
Founding of the company in Stuttgart by Wilhelm Bock and
Hans Göldner
Production for the first time of open refrigerating machines and
relocation to Nürtingen to a larger factory building
1955
1966Development and construction of automobile air conditioning
(installed in the VW Beetle)
1970 Expansion of the product range to vehicle compressors and larger
stationary compressors
1993Relocation of Administration to Frickenhausen
1994 Introduction of the semi-hermetic HA (hermetic
air-cooled) and HG (hermetic gas-cooled) series
1996Introduction of the FK40 vehicle compressor
2007
2011
2012
New Training Center
Bock becomes part of the GEA Group
New production hall and warehouse
History
Construction of a new subsidiary factory in Frickenhausen (initial production area of 1,000 m²)
5
References
Leading manufacturers, such as MAN in the team bus of the soccer team
Borussia Dortmund, rely on GEA Bock FK compressprs for bus air
conditioning.
Semi-hermetic GEA Bock compres-sors are responsible for the reliable refrigeration of food and drinks in
restaurants - as here in the Sausalitos in Stuttgart.
GEA Bock compressors ensure that food and fresh produce is refrigera-ted in ideal conditions at countless
supermarkets (e.g. in the COOP supermarket in Birsfelden or in the
REWE branch in Fulda).
GEA Bock compressors ensure optimum provision cooling
on the high seas (e.g. on the cruise ship
AIDA Aura).
6
Production
1
2
3
4
5
6
7
Central Customer Service / Repair
Manufacturing
Measurement room
Presetting tools
Cleaning facility
Preparation of the compressor housing
Compressor assembly
7
8
9
10
11
12
13
14
Test-bench
Paint shop
Electrical assembly
Assembly of the condensing units
Final assembly and dispatch
Goods-in inspection
Warehouse
8
Station 1: Central Customer Service / Repair
- Inspection of the compressors
- Analyzing the cause of the breakdown
- Support / information on solving the problem
Factory Tour
Station 2: Manufacturing
- Setting up the blank housing ready for machining
- Machining and resetting of the blank housing (change of position)
- Checking functional dimensions in the manufacturing process (QA)
9
Station 3: Measurement room
- Measuring the finished compressor housing for dimensional accuracy
- Checking all delivered parts on a sample basis by means of a test schedule
Factory Tour
Station 4: Presetting tools
- Measuring and adjusting tools for e.g. CNC centers
- Possible corrective actions are integrated into the manufacturing process
- Tool management: approx. 1000 tools are catalogued
10
Station 5: Cleaning facility
- Cleaning of finished parts
- Cycle time: 6-7 minutes // washing temperature: 90°C
- Removal of grease, oil and machining chips
Factory Tour
Station 6: Preparation of the compressor housing
- Sight glasses
- Connection seals
- Cylinder roller bearings
11
Station 7: Compressor assembly
- Assembly of the compressors
- Assembly of semi-hermetic compressors and vehicle compressors (2 production lines)
Factory Tour
Station 8: Test-bench
- Checking all compressors for hermetic integrity and any leaks
- Tests on the motor side and on the compressor side
- Different tests on FK compressors and semi-hermetic compressors
12
Station 9: Paint shop
- Color application for the compressors
- Paint finish with 2-component RAL 5000 paint; special paint for ATEX compressors
Factory Tour
Station 10: Electrical assembly
- Electrical assembly of the compressors
- Installation of the motor protection (MP10)
- Installation of the terminal board connection and PTC thermistor
13
Station 11: Assembly of condensing units (optional)
- Construction of a condensing unit with a previously tested compressor
- Final leak search (helium test)
- Assembly takes place in the new production hall
Station 12: Final assembly and dispatch
- Completion / final stage (e.g. adding of operating manuals)
- Dispatch of the compressors to the customers
Factory Tour
14
Factory Tour
Station 14: Warehouse
- Barcode reader and EDP acquisition
- “First In First Out” // “Just In Time”
Station 13: Goods-in inspection
- Testing parts on a sample basis
- Testing by means of pre-established schedules / specifications
15
GEA Bock India Pvt. Ltd.
Vadodara, India
Assembly
Approx. 65 % FK compressors, 35 % all the other compressors
GEA Bock Compressors (Hangzhou) Co., Ltd.
Hangzhou, China
Production and assembly
Primarily FK compressors
Other production sites
GEA Bock Czech s.r.o.
Stribro, Czech Republic
Production and assembly
Mainly semi-hermetic compressors
GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.
We live our values. Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Refrigeration Technologies
GEA Bock GmbH
Benzstraße 7, D - 72636 FrickenhausenPhone: +49 7022 9454-0, Fax: +49 7022 [email protected], www.bock.de, www.gea.com ©
GEA
Gro
up A
G. A
ll rig
hts
rese
rved
. 07/
2013
– R
T-00
4-02
00-U
S-EU