EMKA guides HVAC OEM through component manufacturing changes

2 min read

HANSA develops and produces air-conditioning and ventilation systems for schools, offices, sports halls, swimming pools, hospitals, industry and IT rooms.

Except for a few standard units, HANSA specialises in customised production. Within limits allowed by the respective standards and directives, the company manufactures customised units according to the room ventilation requirements.

The HANSA unit build concept is based on a frame constructed of aluminium profiles and double-skin cladding elements made of galvanised and coated steel sheets with an intermediate insulation layer. All system components must maintain either positive or negative pressure as required to regulate the temperature and air exchange in entire building complexes. The proper locking technology is an integral part of the enclosures to ensure the desired compression and easy and safe operation during maintenance.

HANSA Klimasysteme and EMKA have been working together to reliably lock complex air conditioning and ventilation units with fittings and gaskets for over two decades. EMKA locks comply with the special ventilation and air-conditioning systems requirements and fulfil the corresponding standards such as DIN EN 1886 or VDI 6022.

Their latest project focused on replacing existing components. Aluminium parts are used as connecting elements at the corners of the air-conditioning units to stabilise the housing cube. The latest joint project was the changeover from aluminium mould parts to die-cast aluminium parts. The difference in production is that, compared to gravity die casting, the metal is injected into the mould cavity under pressure in pressure die casting, with consequent increase in quality and reduction in piece price for larger quantities.

“Since our instruments have had continuously higher sales, the quantities of these systems have increased accordingly,” explains Arno Bunger, production manager at HANSA. “From a certain number of units onwards, it is worth switching to die-casting. Even if the mould is more expensive, the components are ultimately much cheaper.”

Every year, approximately 8,000 parts are used in the joint project started at the end of 2019. Having been asked how to change the existing component to make it suitable for aluminium die casting, EMKA then created compliant engineering drawings and had the appropriate tools manufactured. The key demand for the aluminium die-cast parts was that above all, they must be stable and have an exact geometry. Moreover, the price had to be fundamentally reduced compared to mould production.

EMKA made the previous aluminium mould part suitable for die-casting and used a precisely fitting geometry.

HANSA were able to switch to parts made of die-cast aluminium with various EMKA fittings, ranging from hinges to levers on the operating doors. Hygienic sealing gaskets made of EPDM and silicone are also used in these units to seal them pressure-tight and to ensure the systems’ durability.

Bunger referred to future collaborations: “EMKA is proven because of its high delivery capacity. Moreover, the team around our contact persons is very committed, competent and makes short-notice enquiries possible quickly.”

The next project is already being planned to convert hinges previously manufactured in-house to EMKA’s new innovative 2D hinges with raised hinge bracket.