Manufacturer of industrial fans and fan wheels from one-off production to large-scale series
Karl Klein Ventilatorenbau GmbH
Aichwald (Headquarters) · Petersberg (Thuringia) · Crailsheim (Kamptmann GmbH)New on Amplifa
About Karl Klein
Karl Klein Ventilatorenbau GmbH has been developing and manufacturing centrifugal fans and industrial fans for a wide range of industrial applications since 1950. The portfolio includes low-, medium- and high-pressure fans, boiler and dust fans, plug fans for media temperatures up to 450 °C, hot gas circulators up to 1200 °C and mobile ATEX fans; volume flows reach up to 650,000 m³/h. Production is carried out with a high level of vertical integration in steel, stainless steel (V2A/V4A), aluminium, nickel and titanium alloys – from laser cutting and 3D welding robots to in-house toolmaking. Product development uses 3D CAD, CFD flow simulation and FE analysis; an in-house DIN chamber test rig is used for performance measurement. Fan wheels up to 2500 mm in diameter are manufactured, balanced and repaired by the subsidiary Kamptmann GmbH in Crailsheim. Customers come, among others, from mechanical and plant engineering, baking technology, the rail, shipbuilding and wind power industries, chemicals and HVAC technology.
- Site
- Aichwald
- Processes
- Manufacture of industrial fans (centrifugal fans) in series or one-off production, Laser cutting, Laser welding, Welding (3D welding robots), Sheet metal bending / press braking, Toolmaking incl. die sinking (electrical discharge machining), Manufacture of fan wheels (impellers) welded or riveted (roller riveting process), Machining of fan wheels
- Materials
- Sheet steel, Steel 1.0570 (ST52-3), Fine-grain structural steel 1.8928 (NAXTRA 700), Stainless steel V2A, Stainless steel V4A, Nickel alloys, Titanium alloys, Aluminium
- Certificates
- DIN EN ISO 9001 (quality management system, certified since 1996; website, DIN EN 15085-2 welding certification level CL2 (rail vehicles), ISO 9001, EN 15085-2 CL2 (welding certification rail vehicles)
- Founded
- 1950
- Employees
- 123
- 01
3D-CAD design with CFD and FE simulation
- 02
Laser cutting
- 03
Sheet metal bending (press brake)
- 04
Welding (3D welding robots, laser welding)
- 05
Toolmaking incl. die sinking
- 06
Manufacture and balancing of fan wheels (Kamptmann)
- 07
Painting
- 08
Assembly
- 09
Performance measurement on the DIN chamber test rig
- 10
Service, warranty, maintenance
Materials and Processes
Steel 1.0570 (ST52-3)
High-strength structural steel for impellers and housings of highly stressed fans.
Fine-grain structural steel 1.8928 (NAXTRA 700)
Very high-strength material for blades of high-performance fans.
Stainless steel V2A
Corrosion-resistant version for aggressive media and food applications.
Stainless steel V4A
Seawater- and chemical-resistant stainless steel version.
Aluminium
Lightweight material for fan wheels in single-item and small-series production.
Nickel alloys
For corrosive and thermally highly stressed applications in the laser welding process.
Titanium alloys
For particularly demanding media and temperature conditions.
Heat-resistant steels
For plug fans up to 450 °C and hot gas circulators up to 1200 °C, resistant to grain decay and creep.
Sites
Aichwald
DEMain plant: production, development, administration
- Lot size
- Single items to series production
- Materials
- Steel, stainless steel, aluminium, nickel and titanium alloys
- Bystronic Bystar 4020 laser cutting machine (4.4 kW)
- Trumpf laser cutting machine 1030
- Laser cutting machine (new 2024)
- Laser welding machine (2024)
- 3D welding robot
- Trumpf press brake 1300 kN, bending length 3230 mm
- Die sinking machine for toolmaking up to 1000 kg workpiece weight
- DIN chamber test rig
Petersberg
DEThuringia plant: production of large series, sales, customer service, service
- Lot size
- Large series up to 650,000 m³/h
- Materials
- Steel, stainless steel
- Two laser cutting machines (since 2016)
Crailsheim
DESubsidiary Kamptmann GmbH: fan wheel production
- Lot size
- Single items as well as small and medium series
- Materials
- Aluminium, steel, stainless steel
- 3D welding robot
- System for balancing wheels up to 2500 mm diameter
Components
Inside the production
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of industrial fans (centrifugal fans) in series or one-off productionAssembly | – | – | – | Single items to series production | Sheet steel, Stainless steel (V2A, V4A), Aluminium |
| Laser cuttingMachining | – | – | – | – | Steel, Stainless steel, Aluminium |
| Laser weldingJoining | – | – | – | – | Steel, Stainless steel, Nickel alloys, Titanium alloys |
| Welding (3D welding robots)Joining | – | – | – | – | Steel, Stainless steel |
| Sheet metal bending / press brakingForming | – | Bending length 3230 mm | – | – | Sheet steel, Stainless steel |
| Toolmaking incl. die sinking (electrical discharge machining)Machining | – | – | up to 1000 kg workpiece weight | – | Steel |
| Manufacture of fan wheels (impellers) welded or riveted (roller riveting process)Joining | – | Diameter up to 2500 mm | – | Single items – Small and medium series | Aluminium, Steel, Stainless steel |
| Machining of fan wheelsMachining | – | Diameter up to 2500 mm | – | – | Aluminium, Steel, Stainless steel |
| Balancing of fan wheelsTesting | – | Diameter up to 2500 mm | – | – | Aluminium, Steel, Stainless steel |
| Design and development with CAD, flow simulation (CFD), strength analysis (FE)Engineering | – | – | – | – | – |
| Performance measurement of fans (DIN chamber test rig)Testing | – | – | – | – | – |
| Manufacture of hot gas circulators for temperatures up to 1200°CAssembly | – | – | – | – | heat-resistant steel, stainless steel |
| Manufacture of plug fans up to 450°CAssembly | – | – | – | – | heat-resistant steels, stainless steel |
| Painting (e.g. FDA-compliant painting)Surface | – | – | – | – | Steel, Stainless steel |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 3D welding robot | – | 2 | – | 2014 | Aichwald and Crailsheim |
| Laser cutting machine | Bystronic Bystar 4020 | 1 | 4.4 kW | – | Aichwald |
| Laser cutting machine | Trumpf 1030 | 1 | – | – | Aichwald |
| Laser cutting machine (new) | – | 1 | – | 2024 | Aichwald |
| Laser welding machine (new) | – | 1 | – | 2024 | Aichwald |
| Press brake (sheet bending machine) | Trumpf | 1 | Press force 1300 kN, bending length 3230 mm | – | Aichwald |
| Die sinking machine (toolmaking) | – | 1 | Workpiece weight up to 1000 kg | – | Aichwald |
| DIN chamber test rig | – | 1 | – | 1988 | Aichwald |
| Laser cutting machine | – | 2 | – | 2016 | Eisenberg (today Petersberg) |
Additional services
Reference customers
Quality
The quality management system is certified to DIN EN ISO 9001 (since 1996); in addition, the welding certification DIN EN 15085-2 CL2 for rail vehicles is held. For fan performance measurement, an in-house DIN chamber test rig is available.
| Evidence | Aichwald | Petersberg | Crailsheim |
|---|---|---|---|
| ISO 9001 | |||
| EN 15085-2 CL2 (welding certification rail vehicles) |