Develops and manufactures technical injection-moulded parts and assemblies made of plastic for Automotive and Industries.
GEALAN Formteile GmbH
Oberkotzau · Hof · Hof (Haidt) · Munich · Aš (Krásná) · SzékesfehérvárNew on Amplifa
About GEALAN Formteile
GEALAN Formteile is a development and series supplier of technical plastic components headquartered in Oberkotzau in Upper Franconia. The owner-managed family company, whose roots go back to 1921, has been producing injection-moulded parts and assemblies since 1985: from classic single-component injection moulding on machines with clamping forces of up to 24,000 kN, through 2K injection moulding, thermoplastic foam moulding (TSG/MuCell) and insert technology, to plastic welding processes, PUR foam sealing (FIPFG), finishing and automated assembly including end-of-line inspection. In-house development and design capacity with CAD, simulation, rapid prototyping as well as measurement and testing complements production. A part weight of up to 6.4 kg in single-component injection moulding and an annual output of around 110 million articles with 10,500 tonnes of processed granulate document the industrial scale. The group operates six sites in Germany, the Czech Republic and Hungary with more than 700 employees. Application fields are the automotive industry, especially premium vehicles, as well as the heating and hot-water sector and industrial supply.
- Site
- Oberkotzau
- Processes
- Single-component injection moulding, Two-component injection moulding, TSG - Thermoplastic foam moulding (chemical and physical/MuCell), Insert technology (manual, semi- or fully automated), Vibration welding, Spin welding, Ultrasonic welding, Hot plate welding
- Materials
- Plastic granulate, PUR, Single-Component Injection Moulding, Two-Component Injection Moulding, Thermoplastic Foam Moulding (chemical/MuCell), Insert Technology, Plastic Welding, PUR Foaming
- Certificates
- IATF 16949, ISO 9001, ISO 45001, ISO 50001, ISO 14001, TISAX
- Founded
- 1985
- Employees
- 700
- Industries
- Automotive, Heating and hot-water sector, Industries
- 01
Development and Design
- 02
Simulation and Rapid Prototyping
- 03
Injection Moulding (1K, 2K, TSG)
- 04
Insert Technology
- 05
Plastic Welding
- 06
PUR Foaming
- 07
Finishing
- 08
Assembly
- 09
End-of-Line Inspection
- 10
Logistics
Materials and Processes
Single-Component Injection Moulding
Classic process for technical parts up to 6.4 kg part weight on machines with clamping forces of up to 24,000 kN.
Two-Component Injection Moulding
Processing of two materials in one step, joined by material bond or mechanical interlock, on machines up to 5,500 kN.
Thermoplastic Foam Moulding (chemical/MuCell)
Foam structure in the core of the part for lightweight construction, minimised warpage and dimensional stability.
Insert Technology
Inserts placed manually, semi- or fully automatically are overmoulded.
Plastic Welding
Vibration, spin, ultrasonic, hot plate and laser welding for pressure-tight, function-integrating components.
PUR Foaming
Application of seals directly onto the 3D contour, thixotropic and liquid PUR systems as well as Xgea speed foams.
Development, Simulation, Rapid Prototyping
Design and validation of design and functionality before series start-up.
Polyurethane (PUR)
Material for foam sealing directly onto part contours.
Sites of the GEALAN Formteile Group
Oberkotzau
DEHead office, R&D project management, production plant incl. assembly, logistics centre
- Injection moulding machines incl. large-machine hall
Hof
DEProduction plant incl. assembly (Plant 2)
Hof (Haidt)
DER&D centre: design, simulation, measurement and testing (CAXsolutions GmbH)
Munich
DER&D office, development collaboration with BMW and partners in southern Bavaria
Aš (Krásná)
CZAssembly plant (GEALAN Czech s.r.o.)
- Assembly machines
- Plastic welding systems
Székesfehérvár
HUProduction plant incl. assembly, logistics centre (GEALAN HungaryPlast Kft.)
- 1K injection moulding machines up to 10,000 kN
- PUR foaming systems
- Hot plate and vibration welding technology
- Assembly and automation
Components and Applications
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Single-component injection mouldingPlastics | – | – | 6.4 kg | – | – |
| Two-component injection mouldingPlastics | – | – | – | – | – |
| TSG - Thermoplastic foam moulding (chemical and physical/MuCell)Plastics | – | – | – | – | – |
| Insert technology (manual, semi- or fully automated)Plastics | – | – | – | – | – |
| Vibration weldingJoining | – | – | – | – | – |
| Spin weldingJoining | – | – | – | – | – |
| Ultrasonic weldingJoining | – | – | – | – | – |
| Hot plate weldingJoining | – | – | – | – | – |
| Laser weldingJoining | – | – | – | – | – |
| Heated tool weldingJoining | – | – | – | – | – |
| PUR foaming (FIPFG, thixotropic and liquid PUR systems, Xgea speed foams)Plastics | – | – | – | – | – |
| Assembly (manual and fully automated, incl. end-of-line inspection)Assembly | – | – | – | – | – |
| FinishingSurface | – | – | – | – | – |
| Development and design (CAD, simulation, scans, rapid prototyping)Engineering | – | – | – | – | – |
| Measurement and testingTesting | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection moulding machines | – | 90 | Clamping forces up to 24,000 kN | – | Group (Oberkotzau, Hof, Székesfehérvár) |
| Injection moulding machines | – | 9 | 350 – 7,500 kN clamping force | 1985 | Oberkotzau |
| Welding systems | – | 21 | – | – | – |
| PUR foaming systems | – | 6 | – | – | – |
| 2K injection moulding machines | – | – | up to 5,500 kN clamping force, index rotary table, turntable and latch shuttle tools | – | – |
| Foam injection moulding machines (MuCell/chemical) | – | – | up to 10,000 kN clamping force | – | – |
| Assembly machines | – | – | – | – | Krásná (Aš) |
Additional services
Reference customers
Quality and Management Systems
Quality is safeguarded group-wide through standardisation as well as modern inspection and measurement systems; the zero-defect principle is the goal of our work. From development and industrialisation to the finished component, regular quality inspections are carried out according to customer specifications.
| Evidence | Oberkotzau | Hof | Hof (Haidt) | Aš (Krásná) | Székesfehérvár |
|---|---|---|---|---|---|
| ISO 9001 | |||||
| IATF 16949 | |||||
| ISO 45001 | |||||
| ISO 14001 | |||||
| ISO 50001 | |||||
| TISAX |
Milestones since 1921
- 1921
Foundation of Bayerische Fellverwertung by the Fickenscher family
- 1985
Foundation of GEALAN Formteile in Oberkotzau with DM 12 million investment and 9 machines (350–7,500 kN)
- 1993–1995
Process specialisations: two-component injection moulding technology, vibration welding, PUR foam sealing
- 1997
Start of the first in-house CAD activities
- 1998–1999
Acquisition of Plant 2 in Hof; new administration building in Oberkotzau
- 2002–2017
Three-time award as one of the 50 fastest-growing medium-sized companies in Bavaria (Bayerns Best 50)
- 2004
Re-establishment of GEALAN CAXsolutions as a development centre
- 2006
Foundation of GEALAN Czech s.r.o. in Aš, first foreign site
- 2007–2010
Expansion of Plant 1 with a large-machine hall; logistics +4,000 sqm; opening of Plant 3 (assembly) in Oberkotzau
- 2013–2018
Introduction of TSG foam injection moulding (MuCell), machines up to 10,000 kN
- 2014–2015
Acquisition and commissioning of GEALAN HungaryPlast in Székesfehérvár
- 2016
Opening of the Munich office (proximity to BMW)
- 2018–2020
Hungary plant +10,000 sqm to 20,000 sqm; Czech assembly site +1,500 sqm
- 2021
Target of CO2 neutrality by 2030 (GEALAN goes Zero CO2)
- 2022–2023
Entry of the 4th generation: Timo Fickenscher and Jonas Laubmann