This new technology can definitely be called a "revolution" in the automotive industry.
With the development of SealMatic®, we have succeeded in offering seals that can be cut to the required finished dimensions fully automatically and assembled with multifunctional robot systems only immediately before they are fitted to the respective vehicle.
For this purpose, SealMatic® is manufactured in lengths of up to 1,400 meters in specially developed production equipment and wound fully automatically onto a special load carrier.
During production, every centimeter of the endless sealing strand is monitored by 3D camera systems and laser units, which detect unauthorized geometric deviations or surface defects and mark defective sealing areas. If the defective areas exceed precisely defined intervention limits, these areas are cut out fully automatically without interrupting the production process, and the gasket is rejoined to the endless strand by means of butt splicing.
Until the use of our endless technology, it was not common practice to coil seals, as there was a risk of deformation due to excessive stresses during the winding process and/or pressure from the layers above. Using exceptional simulation methods, SaarGummi was able to develop a seal cross-section in a project phase lasting several years which, in combination with special rubber compounds and a new winding technology, shows no deformation even after months of storage.
As a result, SealMatic® can be produced in a packing density previously not thought possible and wound onto the special load carrier developed for this purpose. Compared to the packaging units previously used on the market, a doubling of the packing density is thus achieved. Due to the above-average overall performance of the system, in which environmental friendliness was also considered in addition to the technical and commercial aspects, the SaarGummi Group was nominated in 2011 as one of five finalists in the category of medium-sized companies for the "Innovation Award of the German Economy - First Innovation Award of the World®".
Christian Kast: not only an inventor of innovations, but also committed to sustainability…
In his current position, the introduction of new, highly digital systems for so-called “virtual development”, which considerably reduce the number of time-consuming and cost-intensive prototypes, and ensure a high-quality development performance for our existing but also new customers with different requirement profiles, means that there is never a dull moment in his daily work routine.
In addition, the topic of “sustainability” is particularly close to the 53-year-old family father’s heart and so he pays special attention to how we can adapt our sealing system to the advancing requirements of recycling and sustainability. In the contect also the installation of the e-charging stations at the Büschfeld site is due in no small part to his initiative.
Our focus now and in the future: the issue of sustainability
For many years now, we have been able to look back on a well-functioning and certified environment and energy management system.
Be it the SealMatic® continuous seal, the construction of e-filling stations, the recycling of waste, or a new CHP plant: all these measures contribute to saving energy and to environmental protection.
Even in the development of our products, we already consider the use of resources. This continues from the procurement of materials by our purchasing department via the manufacture of our products through to the ultimate waste disposal. We strive to be as environment-friendly as possible in the manufacture of our rubber products. It is for this reason that we do not use natural rubber, but synthetic rubber made from ethylene propylene diene monomer (EPDM).
We are also currently working on a number of other innovations that additionally contribute to sustainability in terms of durability, new raw materials, weight, devulcanization, packaging, and upcycling.
To give the sustainability aspect the importance we live by within the company, we have also created the function of Global Corporate Social Responsibility Agent.
Corporate Carbon Footprint (CCF), our materiality matrix and our environmental product declaration form the basis for the effective implementation of climate protection measures.
The sustainability issue is also increasingly being pushed by our customers in their supplier portals. The topic of “emissions reduction” will continue to play an immensely important role in the future, leading up to a fully climate-neutral production. This is also our declared goal.
Irrespective of this, we are always looking to achieve additional savings in the use of energy and materials.
