Production – quality and technology
Quick delivery times – fast and fresh
A very high supply capability is part of the company’s basic principle. To ensure this, we systematically analyse the seasonal, short- and long-term trends using systems, and are therefore able to adjust our stock liability daily to the new requirements and the current demand trends. Our aim is to ensure the immediate supply of all standard products up to large, normal order quantities at all times. At the same time, we also implement a system to ensure the products we manufacture are fresh at all times, and they are in stock. We also manufacture complete batches to order for specific customers or major customers in Germany and worldwide, which are often necessary for long transport routes, for example to Russia, the USA, China or Australia. Two large shipping halls with four parallel truck docking stations enable fast processing for small and large orders. Everything is fully traced by location and batch, from raw material to finished product. This is how we support our customers with high supply capability – fast and fresh.
Flexibility
We at [Z] BERGER-ZOBEL focus on flexibility. The production facility has the capacity to manufacture batches from 1 kg to 15,000 kg. The adjacent dispatch area therefore has the sufficient flexibility to prepare small orders and full container and jumbo loads for order picking. We implement job rotation, which enables us to deploy a large number of employees in a versatile way and therefore also respond effectively to bottlenecks.
State-of-the-art production technology
Berger makes regular and sustainable investments into the state-of-the-art production technology. In this way, we not only achieve the flexibility described above, but also a modern standard of production reliability and efficiency. System-supported processes, both semi- and fully automated, assist the competent team of employees and help prevent and identify human error and to enable perfectly identical processes for subsequent production processes, regardless of the operator. The machinery includes all the relevant and latest equipment and processes, e.g., vacuum isolators for adhesive production, bead mills for perfect painting processes, Incan-small-batch plants with production directly into the sales container, automatic wrapping and shrinking machines for optimal load securing, small and large dissolvers for all batch sizes, small and large semi- and fully automated filling plants, parameter-controlled and closed process control, and much more.
Quality assurance to the power of 3
Nothing comes as high in the priority of our actions as the safety of our products at the highest level of quality. For this reason, we implement quality assurance to the power of 3 in the production department and for every product: Firstly, for each raw material, secondly, for each semi-finished or intermediate product, and thirdly, for each finished product. Our laboratory precisely defines the respective criteria and target values in each individual case. These are permanently tested and monitored for each batch, and approval is only granted if they comply in full, with safety to the power of 3.
High level of process engineering expertise
Advanced and specialised process engineering expertise and competent production personnel ensure the implementation of new product developments in small and large-scale production. Production speed and quality assurance are achieved through close coordination between the departments. An extensive training system ensures the expertise, high motivation, commitment and versatility of employees.
Premises
Our company premises covers approx. 24,000 sqm, and is the ideal space for all the plants, buildings and logistics, with potential for the further development of the company for decades to come. We organise and manage our logistics effectively with thousands of pallet spaces on an area of thousands of square metres of production and storage. Many dozens of tanks are available for raw materials, with capacities of up to 30,000 litres, which are partially underground, partially in temperature-controlled halls to ensure optimum efficiency in purchasing and logistics.
Occupational safety and environmental protection
Based on the consistent safety system, production processes take place based on the principle to minimise risk at all times. A comprehensive environmental and occupational safety management system has been implemented to achieve this objective. We have installed effective fire compartmentation, fire alarm systems, extinguishing water capacities, regular drills and safety training, safety officers, production monitoring systems, room sensor systems, ergonomic work aids, tank filling using the gas displacement method, solvent distillation and much more stand to achieve our high occupational safety and environmental standards.
