Manufacture of switchgear cabinets, marine electrics, sheet metal and laser technology as well as electrical machine construction from Elmshorn
Zoller GmbH
Elmshorn, Otto-Hahn-Straße 9New on Amplifa
About Zoller GmbH
Zoller GmbH is a family-run electrical contractor based in Elmshorn, founded in 1916 and today employing around 140 staff. From an original motor workshop, six fields of activity have developed: switchgear and control cabinet construction (low, medium, high and extra-high voltage), electrical machine construction, marine electrical equipment, sheet metal and laser technology, painting technology as well as heating & plumbing. In switchgear construction, control cabinets, main and emergency switchboards, bridge consoles and control systems are designed in 3D using the EPLAN and EPLAN ProPanel planning software tools and manufactured on fully automated systems – including a 3D laser center Perforex LC3030 for control cabinets up to 4 mm material thickness, a sheet metal processing center, an automatic terminal assembly machine and fully automatic cable assembly (single cores 0.5–95 mm², printing up to 2000 m of cable length). In electrical machine construction, drives are serviced, rewound and commissioned under load on a test field with up to 350 kW. Application sites include ships, wind turbines, charging parks and biogas plants; customers range from commercial businesses to private households. All services are provided at the Elmshorn site from a single source.
- Site
- Elmshorn
- Processes
- Sheet metal processing (cutout work, punching, milling, drilling, tapping, special paint finishes), 3D laser processing of control cabinets (Lasercenter Perforex LC3030), Laser cutting of workpieces (up to four workpieces at the same time, 3D, up to 4 mm thickness), Laser marking (signs, cable markings, terminal markings, type plates), DIN rail assembly (cutting to length, engraving, populating, labeling), Fully automatic cable assembly (cutting, labeling, ferrule termination, chain-, Switchgear construction and control system construction (planning, design, manufacturing, testing,, Marine electrical equipment (main/emergency switchboards, bridge consoles, motor switching gear,
- Materials
- Stainless steel, Plastic, Aluminum, Brass, 3D laser processing, Fully automatic sheet metal processing, Fully automatic cable assembly, Laser marking
- Certificates
- ISO 9001, ISO 50001, EN 12101-2, DGUV V52 & V54
- Industries
- Shipbuilding and offshore, Wind energy, Biogas/energy infrastructure, Energy industry, Building technology, Industrial plants
- 01
Requirement definition
- 02
3D design (EPLAN/EPLAN ProPanel)
- 03
Sheet metal processing & 3D laser processing
- 04
DIN rail assembly & cable assembly
- 05
Assembly & wiring
- 06
Testing/FAT on the test field
- 07
Shipping or on-site commissioning
Materials & Processes
3D laser processing
Contactless, low-vibration processing of control cabinets and sheet metal up to 4 mm material thickness, up to four workpieces at the same time.
Fully automatic sheet metal processing
Cutout, drilling, tapping and milling work on individual sheets and larger quantities, e.g. control cabinet base plates and enclosures.
Fully automatic cable assembly
Cutting, labeling and ferrule termination of single cores 0.5–95 mm², printing up to 2000 m of cable length.
Laser marking
Signs, cable and terminal markings on stainless steel, plastic, aluminum and brass.
Painting technology
Industrial and special paint finishes of components, vehicle painting and classic car restoration.
Locations
Elmshorn
DEHeadquarters, manufacturing, workshop, test field and retail store
- Lot size
- Single items to series production
- Materials
- Stainless steel, aluminum, brass, plastic, copper
- 3D laser center Perforex LC3030
- Fully automatic sheet metal processing center
- Automatic terminal assembly machine
- Fully automatic cable assembly system
- Test field up to 350 kW
- Balancing machine (length 4 m, Ø 1.6 m, 3.5 t)
- Winding machine
- Hot cleaning oven
- Vibroport measuring device
- Baker surge voltage tester
- Lathes and milling machines
- High-voltage and insulation testing devices
Products & Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Sheet metal processing (cutout work, punching, milling, drilling, tapping, special paint finishes)Machining | – | – | – | Individual sheets | – |
| 3D laser processing of control cabinets (Lasercenter Perforex LC3030)Machining | – | – | – | Prototypes – Series production | Stainless steel |
| Laser cutting of workpieces (up to four workpieces at the same time, 3D, up to 4 mm thickness)Machining | – | – | – | – | – |
| Laser marking (signs, cable markings, terminal markings, type plates)Surface | – | – | – | – | Stainless steel, Plastic, Aluminum, Brass |
| DIN rail assembly (cutting to length, engraving, populating, labeling)Assembly | – | – | – | – | – |
| Fully automatic cable assembly (cutting, labeling, ferrule termination, chain-Assembly | – | – | – | – | Copper (cables/wires) |
| Switchgear construction and control system construction (planning, design, manufacturing, testing,Assembly | – | – | – | – | – |
| Marine electrical equipment (main/emergency switchboards, bridge consoles, motor switching gear,Assembly | – | – | – | – | – |
| Electrical machine construction (maintenance, rewinding, overhaul, repair of electric motors/drives)Assembly | – | – | – | – | – |
| Servo motor repairAssembly | – | – | – | – | – |
| Test field acceptance under load up to 350 kW (quality control, FAT tests)Testing | – | – | – | – | – |
| Crane technology (inspection, maintenance, overhaul, repair, assembly/disassembly of crane systems)Assembly | – | – | – | – | – |
| Full-service support of biogas plants (agitators, blowers, pumps, CHP generators, sensor technology)Assembly | – | – | – | – | – |
| Painting technology (vehicle painting, restoration, industrial and special paint finishes)Surface | – | – | – | – | – |
| E-Check (testing of portable equipment per DGUV regulation)Testing | – | – | – | – | – |
| Electrical installationAssembly | – | – | – | – | – |
| Heating & plumbing (new construction, maintenance, renovation, pipe inspections, building drying,Assembly | – | – | – | – | – |
| ThermographyTesting | – | – | – | – | – |
| Energy management systems to DIN EN ISO 50001Engineering | – | – | – | – | – |
| Motor winding (rewinding of electric motors)Assembly | – | – | – | – | – |
17 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Lasercenter Perforex LC3030 (3D laser processing of control cabinets) | Perforex LC3030 | 1 | – | – | Elmshorn |
| Laser processing center (up to 4 mm material thickness, 3D, 4 workpieces at the same time) | – | 1 | – | – | Elmshorn |
| Laser printer (laser marking) | – | – | – | – | Elmshorn |
| Fully automatic sheet metal processing center | – | 1 | – | – | Elmshorn |
| Fully automatic terminal assembly machine | – | 1 | – | – | Elmshorn |
| Fully automatic cable assembly system | – | 1 | Printing up to 2000 m of cable length (dip bath) | – | Elmshorn |
| Vibroport measuring device (mobile alignment, vibration measurement) | Vibroport | 1 | – | – | Elmshorn |
| Thermal hot cleaning oven (degreasing/de-painting) | – | 1 | – | – | Elmshorn |
| Balancing machine (dynamic or static) | – | 1 | Length 4 m; diameter 1.6 m; weight 3.5 tonnes | – | Elmshorn |
| Winding machine for rewinding of electric motors | – | 1 | – | – | Elmshorn |
| Baker surge voltage tester | Baker | 1 | – | – | Elmshorn |
| Laser alignment | – | – | – | – | Elmshorn |
| Lathes | – | – | – | – | Elmshorn |
| Milling machines | – | – | – | – | Elmshorn |
| High-voltage and insulation testing devices | – | – | – | – | Elmshorn |
| Vibration measuring device | – | – | – | – | Elmshorn |
| Test field (acceptance under load) | – | 1 | Capacity up to 350 kW | – | Elmshorn |
Additional services
Quality & Certifications
Every switchgear cabinet and control system is tested for flawless function; overhauled machines are commissioned under load (up to 350 kW) in our own test field, supplemented by FAT tests for frequency-controlled bow thruster systems, deck winches and carousel controls. Zoller has been certified to DIN EN ISO 9001 since 2006 and is certified for the inspection of crane systems (DGUV V52 & V54), gate systems (ASR 1.7) as well as smoke and heat exhaust systems (EN 12101-2).
| Evidence | Elmshorn |
|---|---|
| ISO 9001 | |
| ISO 50001 | |
| EN 12101-2 | |
| DGUV V52 & V54 |
History
- 1916
Founded as a motor workshop by Emil Zoller at Köllner Chaussee 48 in Elmshorn
- 1955
Leadership passed to the second generation: Arnold Zoller and Emil Zoller
- 1966
Third generation: Uwe and Elke Zoller take over the leadership
- 1973
Move to the current location at Otto-Hahn-Straße 9
- 1992
Sven-Olaf Zoller joins as managing director; sole owner from 1998
- 1998
Takeover of the crane technology department from the Hamburg-based company Stork-Jaffa
- 2006
First certification to DIN EN ISO 9001
- 2023
Fifth generation: dual leadership by Sven-Olaf Zoller and Johannes Zoller