Manufacture of underpressure tapping fittings, pipe sealing saddles and road covers in cast iron at the Lüneburg site.
KEULAHÜTTE LÜNEBURG Armaturen GmbH
LüneburgNew on Amplifa
About Keulahütte Lüneburg
KEULAHÜTTE LÜNEBURG Armaturen GmbH develops and produces at its Lüneburg site underpressure tapping fittings, tapping valves, tapping saddles, pipe sealing saddles, blank saddles and road covers for wholesalers and gas and water supply utilities as well as pipeline construction. The value chain extends from in-house cast iron through CNC machining of raw castings, welding operations and epoxy powder coating to assembly, leak testing and shipping. Castings are produced in machine-molded sand casting on flaskless DISA molding machines with vertical parting; the melting operation comprises four induction melting furnaces and two automated magnesium treatment stations. The company has been working with this technology for more than 30 years, and in total it can look back on over 50 years of experience in the manufacture of underpressure tapping fittings. The Z tapping system is offered in numerous variants including stainless steel valve bodies as well as versions for Frialen PE fittings, and is completed by tapping machines, installation kits and a sprinkler hydrant.
- Site
- Lüneburg
- Processes
- Cast iron (machine-molded casting, flaskless molding machines with vertical parting,, Machining of raw castings on modern CNC machining centers, Assembly and leak testing on testing machines, Epoxy powder coating, Welding operations (weld-on underpressure tapping fittings), Manufacture of underpressure tapping fittings (Z, ZKP, ZG, Z-Flex, ZE, Z-ELGEF systems), Manufacture of pipe sealing saddles, blank saddles and road covers, CNC machining of raw castings
- Materials
- Cast iron (grey cast iron), Stainless steel (Inox valve bodies), Hexagon nuts A2 (stainless steel), Hexagon nuts CuNiSi, PE (Frialen PE fitting), Epoxy resin (powder coating), Cast iron (grey cast iron, machine-molded sand casting), Stainless steel (ZKP-Inox, Z-Flex-Inox)
- Certificates
- Quality management system, Leak testing on testing machines, Certified casting production
- Industries
- Gas and water supply, Wholesale, Pipeline construction
- 01
Cast iron (DISA molding machines, two-sand system)
- 02
CNC machining of raw castings
- 03
Welding operations
- 04
Epoxy powder coating
- 05
Assembly
- 06
Leak testing
- 07
Logistics & shipping
Materials and Processes
Cast iron (grey cast iron, machine-molded sand casting)
Base material for underpressure tapping fittings, pipe sealing saddles and road covers, produced on flaskless DISA molding machines with vertical parting.
Stainless steel (ZKP-Inox, Z-Flex-Inox)
Stainless steel valve bodies for underpressure tapping fittings with increased corrosion requirements; accessories such as flexible clamps and hexagon nuts in A2.
CuNiSi
CuNiSi hexagon nuts as accessories for flexible clamps of the underpressure tapping fittings.
PE (Frialen PE fitting)
Sealed PE fitting in the ZEP-Fri underpressure tapping fitting system for plastic pipes.
Epoxy powder coating
Corrosion protection of the castings, including versions in RAL 1023 Yellow for gas applications.
Locations
Lüneburg
DEHeadquarters, production (foundry, CNC machining, assembly)
- Materials
- Cast iron, stainless steel
- 4 induction melting furnaces
- 2 automated magnesium treatment stations
- 3 molding machines
- Flaskless molding machine with vertical parting (DISA)
- Two-sand system
- CNC machining centers
- Testing machines (leak testing)
Products and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cast iron (machine-molded casting, flaskless molding machines with vertical parting,Casting | – | – | – | – | Cast iron |
| Machining of raw castings on modern CNC machining centersMachining | – | – | – | – | Cast iron |
| Assembly and leak testing on testing machinesTesting | – | – | – | – | – |
| Epoxy powder coatingSurface | – | – | – | – | Cast iron |
| Welding operations (weld-on underpressure tapping fittings)Joining | – | – | – | – | Cast iron |
| Manufacture of underpressure tapping fittings (Z, ZKP, ZG, Z-Flex, ZE, Z-ELGEF systems)Assembly | – | – | – | – | Cast iron, Stainless steel |
| Manufacture of pipe sealing saddles, blank saddles and road coversAssembly | – | – | – | – | Cast iron |
6 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Induction melting furnace | – | 4 | – | – | Lüneburg |
| Automated magnesium treatment station | – | 2 | – | – | Lüneburg |
| Molding machine | – | 3 | – | – | Lüneburg |
| Flaskless molding machine with vertical parting (DISA) | DISA | – | – | – | Lüneburg |
| CNC machining center | – | – | – | – | Lüneburg |
| Testing machine (leak testing) | – | – | – | – | Lüneburg |
Additional services
Quality
Production is carried out according to the company's own quality management system with leak testing on testing machines; castings are certified and produced under controlled conditions according to modern standards. Thanks to DISA technology combined with a two-sand system, very high mold accuracy, dimensional stability and smooth casting surfaces are possible.
| Evidence | Lüneburg |
|---|---|
| Quality management system | |
| Leak testing on testing machines | |
| Certified casting production |
History
Start of manufacturing activity – over 50 years of experience in the manufacture of underpressure tapping fittings
Introduction of the double-pour casting technology on flaskless molding machines with vertical parting (DISA) – in use for more than 30 years