document7233463554329238930.indd 1 DECEMBER 2019 CUSTOMER MAGAZINE KNOW -HOW MORE CHOICE THE SUPREME MORE VALUE DISCIPLINE FLUSHING SYSTEMS TOOLMAKING 08.11.2019 14:54:01 ON THE COVER The moulds from the toolmaking depart- ment are used at the production facil- ities in Rapperswil-Jona (CH) and Pfullen- dorf (DE). Pictured here is a high-gloss polished mould used for manufacturing the Sigma01 actuator plate.

CONCEPT/DESIGN/REALISATION Linkgroup AG, Zurich www.linkgroup.ch

PHOTOS Ben Huggler (cover, page 14) Iris Cook (pages 6–9) Shutterstock (page 13) SARC Architects/Tuomas Uusheimo (pages 17–18)

Issued quarterly. The reproduction of individual articles, in part or in full, is subject to approval from the editorial staff.

document4160704994437024187.indd 2 08.11.2019 14:53:58 CONTENTS EDITORIAL

6 BEHIND THE SCENES MOULDS WITH MILLI- METRE PRECISION FROM THE TOOLMAK- ING DEPARTMENT Mark Schurr Managing Director 14 COMPETENCES DEAR CUSTOMERS, CALCULATING WATCHMAKING IS A CRAFT THAT SANITARY NOISES IS KNOWN FOR ITS PRECISION.

16 TIPS & TRICKS Similar levels of precision can be found in the in-house toolmaking department at Geberit. With outstanding DESCALING GEBERIT technical skills and a keen eye, toolmakers create moulds AQUACLEAN for injection moulding and blow moulding machines. Accuracy is just as important in the Geberit workshops – and at every work step to boot, starting from the design 5 News data all the way through to honing and then assembling 10 Customer event in Cape Town the individual components to form the finished tool. 13 Geberit Flushing Systems Toolmaking is thus one of the most important success 18 Reference object in Helsinki factors at Geberit. It is not only where all the know-how from product development comes together, but also a source of expertise in production itself as a developer and manufacturer of new moulds. The flawless moulds ensure the undisputed product quality that Geberit is known for.

This issue not only contains more information on the in-house toolmaking department, but also other exciting stories about Geberit and the product range.

I wish you an entertaining and informative read.

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OKTOBERFEST@GEBERIT Fast becoming one of the most antici- pated events of the year. Geberit South- ern Africa held its second annual Okto- berfest. Industry partners were invited for an evening of festivities. The evening was aimed at showing appreciation for relationships and efforts that have as- sisted the Geberit team in South africa grow. The evening was filled with laughs and plentiful conversation. There was also a selection of craft beers as well as German-style cuisine. We look forward to seeing our partners again next year.

SHOWROOM UPGRADES The showrooms at the Geberit offices in Cape Town and Johannesburg will RETIREMENT VALERIE NOBEL be undergoing upgrades. These upgrades The team at Geberit Southern Africa are necessary in order to showcase the would like to bid a fond farewell to Valerie new additions to our ranges. These addi- Nobel who will be retiring at the end tions include the new Geberit myDay of the year. Valerie has been a part of the series, as well as upgrades to the Geberit Geberit team in Cape Town since its Smyle range. If you would like to visit inception 20 years ago. Over the years, one of the Geberit showrooms, please Valerie has become a key member of feel free to contact the office located the logistics team and become an inspir- nearest to you. Our team members would ation to the rest of the team in South be happy to assist you with a walk- Africa for her hard work and dedication. through and answer any technical ques- Valerie will officially become the first tions you may have. member of the team of Geberit Southern Africa to retire. The team at Geberit Southern Africa would like to wish Valerie all the best on her well-deserved break and thank her for her many years of service.

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document2874352365261011448.indd 5 08.11.2019 14:54:02 TOOLMAKING AT GEBERIT THE SUPREME DISCIPLINE

document2074879280042026603.indd 6 08.11.2019 14:54:10 BEHIND THE SCENES

← A look inside the assembly area, where the tools are given their finishing touches.

In order for Geberit to produce first-class plastic components and products, the corresponding injection moulds and blow moulds have to be of the very highest quality and precision. This is the job of the in-house toolmaking department.

The machines in the production halls in Rapperswil- TOOLMAKING = MOULD BUILDING Jona (CH) are running at full steam. Tens of thousands of plastic parts are injection-moulded here every day. Pipe fittings, actuator plates and concealed cisterns – The story is the same at the plant in Pfullendorf (DE). all of these products are made in injection moulding and Without highly automated production facilities with blow moulding machines. The moulds found in these injection moulding and blow moulding machines, machines are produced by the toolmaking department these volumes would not be possible – and certainly (also known as mould building). In the injection mould- not in the precision and surface quality that Geberit ing process, liquid plastic is injected into a mould at strives for. What not many people know is that behind a pressure of up to 2,000 bar, where it then hardens be- this outstanding quality are toolmakers that work at fore the finished component can be taken out of the the very highest level. mould. Due to the high quality standards and the heavy loads they are subjected to, the moulds have to meet HIGHLY CONCENTRATED AND WITH particularly strict requirements. For example, the PINPOINT ACCURACY machining and heat treatment of the wear-resistant The in-house toolmaking departments in Jona and special-grade steel mean that the tool is relatively Pfullendorf specialise in the production of moulds robust. Perfect assembly of the individual components that are required in the injection moulding and blow and a final inspection of the functions ensure that the moulding processes. At the two sites, a total of some liquid plastic then flows into the prefabricated mould as 70 toolmakers, draughtsmen and other specialists go required and that there are no unexpected quality about their tasks in workshops equipped with state- defects on the final product. of-the-art machines. It is immediately clear that qual- ity and precision are of huge importance here. →

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A member of staff painstakingly inspects a compo- “Constructing an injection nent that has been milled from a block of steel by a moulding tool is like computer-controlled machine before they can then combine this with the remaining components to make in Formula 1 – one mistake a complete mould. It’s clear to see that working by and we won’t reach the hand is still in demand here despite the high levels of chequered flag.” automation. “A toolmaker works at a level of precision down to mere one thousandth of a millimetre. Such Michael Zinser accuracy can only be achieved by well-trained staff,” Head of Toolmaking Geberit explains Michael Zinser, Head of Toolmaking. Even the smallest deviation can mean that a mould is rendered useless. Days of work would then have gone to waste in such cases, not to mention the associated financial as the design has to meet the requirements of the in- losses. As Michael Zinser explains: “A finished tool can jection moulding or blow moulding machines exactly. cost several hundred thousand francs.” Special attention is already paid here to the separ- ation of the two halves of the mould. Ventilation and FROM THE BLUEPRINT TO THE FINAL MOULD temperature control of the mould are also already The toolmaking department springs into action when taken into account during this early phase. moulds are worn out or damaged, or when Geberit launches a new product. In the event of new products, Based on the design data, the machine programmers the production of a new mould starts when the prod- then write a CAM program for manufacturing the indi- uct data is passed on by the development depart- vidual components. This program contains all relevant ment. Using this already very precise data – consisting data from the design phase that the CNC machine of 2-D drawings and 3-D data – the draughtsman needs, meaning it can then manufacture the cor- builds the virtual mould on the computer using CAD responding component step by step – ideally in a software. This results in a detailed tool design. Even completely automatic process. Here, the steel plates at this early stage, there is only a low fault tolerance from which the moulds are made are clamped in the machine and then processed using a range of meth- ods, including milling, eroding, turning and grinding. Milling and erosion are used particularly often, with “Our moulds are the former ensuring rotation-symmetric preparation highly complex, precise of easily accessible geometries and the latter used for sharp edges and openings. The components also un- one-off items.” dergo different heat treatment processes.

Michael Zinser Head of Toolmaking Geberit Once the individual components have been prefabri- cated, they are then finished, measured, examined and then assembled into a complete mould. “The as- sembly process is a particularly delicate job that re- quires a lot of experience and a steady hand,” explains Michael Zinser. “In order for the mould to remain in use for a long time, all the components must be perfectly coordinated with one another.”

FAST REACTION TIMES The toolmaking department not only produces new moulds – they are also responsible for the maint- enance and repair of existing ones. Despite the robust materials used, it can happen that a mould can no longer be used as a result of wear or damage. Another benefit of having an in-house toolmaking department comes to the fore here. “External toolmakers are not able to react to unforeseen circumstances with the same level of flexibility as us,” explains Michael Zinser. “Once the production department notifies us of a re- pair, we can start immediately. This flexibility is a major advantage as downtimes at our production facilities should be kept to an absolute minimum.” Depending on the level of damage, the moulds are often back in operation the very next day. ↑ Coordination between manufacturing and assembly is important. The next steps are worked out together.

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Three questions for Michael Zinser, Head of Toolmaking in Pfullendorf (DE) and Rapperswil-Jona (CH) PRECISION IS THE TOP PRIORITY

What are the distinguishing features of toolmaking at Geberit? We have very well-trained, motivated and conscien- tious staff. They often have to work to tight dead- lines, yet always have to deliver perfect results. Pre- cision is the top priority. We are also very flexible. If a tool should give up the ghost during production, we switch things around and take care of the re- ↑ pairs immediately. In this way, we play our part in the A member of staff carefully puts together the two tool parts. punctual delivery of products to our customers.

Why is precision so important in toolmaking? We often only come in when a project is in the im- plementation phase. By this point, a lot of time and money has already been invested in the neces- sary tests and optimisations. Everybody involved wants the new products to be launched on the mar- ket as quickly as possible. However, each quality defect on our tools has direct consequences for the market launch and the product quality.

How long can a tool be used on average? A tool design that has been tested to the limit com- bined with the selection of the best steel for the job lays the foundation for a high-quality tool that causes only minimal follow-up costs across its entire service life and ensures high levels of avail- ability. If the tools are not damaged too heavily, they can remain in operation for decades. Every euro that is invested in the quality of the tool is then paid back with interest across its service life through the lower repair costs. We call this intel- ligent saving.

↑ Using an eyepiece, a member of staff checks whether the surface of the mould core is up to scratch.

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document2074879280042026603.indd 9 08.11.2019 14:54:25 PARTNERSHIP

MEET UP IN CAPE TOWN AN EVENING BENEATH THE STARS

A cold, wet, Capetonian winter’s evening could not stop Geberit industry partners from enjoying night out on the town. Their bravery was rewarded by a wonderfully entertaining evening that was enjoyed by all.

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← Colourlab has brought people together and has helped create lasting memories.

The event was hosted in the heart of Cape Town. A spacious rooftop studio called Colourlab, the venue is the brain child of creative genius, Petra Vonk. It boasts stunning views of the city and its surrounding attrac- tions. It is abuzz with vibrant colours and interesting pieces of art. Every square metre, a talking point. In the planning stages of the event, Petra and her team ↑ worked tirelessly to ensure the event was a success. Think COLOUR and prepare yourself to be delighted and inspired. ATMOSPHERE TO ENJOY Guests were greeted with welcoming cocktails and were serenaded by one of Cape Town’s most promis- ing up-and-coming musical artists, Liam Culbert.

The natural, resonating energy of the room allowed for a relaxing, fun atmosphere. Guests from all parts of the sanitaryware industry were mingling, laughing and exchanging stories from the year that has been. The balcony, which provided a breath-taking view of Table Mountain, was a hotspot for many of our guests, be- fore the cold set in, that is.

An emphasis was put on the gratitude and apprecia- tion that Geberit has for our industry partners. The evening happened to coincide with the anniversary of the opening of the Cape Town branch. The success of which would not have been possible without the help of our industry partners.

Giving in to the cocktail evening, the menu was chock- a-block with bite-sized portions of some delectable meals. This tapas style of serving meant guests were free to mingle and move as they would have liked. This ↑ created an electric atmosphere. Cape Town based singer and guitarist, Liam Culbert, performs for corporate and private events in Cape Town SPECIAL GUEST BRUCE WHITFIELD and surrounds. We were lucky enough to secure one of South Africa’s foremost economic minds to deliver a key note speech to the group, Mr Bruce Whitfield. Mr Whitfield is a well-known, South African personality. He hosts a daily radio show, contributes articles to local news- papers and is a frequent guest on the local news circuit. Mr Whitfield engaged guests in the realities of the South African market. He laid bare that, yes, the South African economy is not in a great place at the moment. But stressed the importance of maintaining an open mind. “Never waste a good crisis,” was his mantra. He pointed out to our guests the importance of being opportunists and the benefits that could be gained by looking to solve the issues currently being experienced in the country.

↑ A special thank you must go out to our partners within Bruce Whitfield is a creative and engaging presenter the industry. We thank you for your continued support who makes money matters understandable and accessible and look forward to fostering these relationships to listeners. throughout the years ahead.

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GEBERIT FLUSHING SYSTEMS MORE CHOICE MORE VALUE

→ Geberit cisterns and actuator plates: the standard for flush technology.

Since 1905 when Geberit released its first cis- tern, an exposed wooden box, Geberit has been at the forefront of flushing technology. Over the years, Geberit has continuously improved on this design. This ultimately led to the creation of the concealed cistern.

Geberit concealed cisterns have been designed to be functional in a variety of installation scenarios. Geberit offers cisterns that can be installed in brick or dry-wall- ing, for wall-hung or floor standing pans. Coupled with the wide selection of actuator plates, which share a name with the appropriate cistern, means that there is truly a Geberit solution for any application.

Geberit has recently introduced its latest concealed Geberit cisterns are designed to be long lasting and cistern advancement: The Geberit DuoFresh. The new easy to use. Still, Geberit offers a ten-year warranty on odour extraction unit brings comfort and fresh air into its cisterns. Geberit also has a 25-year spare part the bathroom. Unpleasant odours are removed right guarantee, ensuring that spare parts should always be where they develop and are purified by an efficient available should they be required. ceramic honeycomb filter. What’s more, a practical orientation light makes it easy for you to find your way Should you wish to view our wide range of products or to the toilet at night. The Geberit DuoFresh module can acquire further information on Geberit products, you be combined with different Geberit actuator plates and are most welcome to visit our offices in Cape Town, can be retrofitted. Durban and Johannesburg.

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CALCULATING SANITARY NOISES VIA COMPUTER “HOW LOUD IS IT GOING TO BE?”

Digital calculation models may be used to predict the extent to which sanitary noises spread in a new residential building. The programs required for this are already in use in some places. Geberit not only supports sanitary engineers and architects by providing the relevant data, but also practical advice.

For many years, Geberit has determined the sound sanitary noises. Given the increasing importance of levels of sanitary installations in its own building tech- computer-generated forecasts for installation noises, nology and acoustics laboratory and had the results Geberit set up a new test facility in the Building Tech- validated by an independent testing institute. Meas- nology and Acoustics Laboratory. This can be used uring results from hundreds of different installation for determining the data that is required for the digital situations and sanitary systems seen in solid con- calculation models. struction projects are now available. Based on this data, which has been determined as part of very real- THE RECEPTION PLATE METHOD istic tests, the acoustics experts at Geberit can as- The first standards for computer-based forecasting sess the sound propagation in building projects with of sound propagation in solid structures have already a high degree of reliability – at least when it comes to been established, with calculation models for instal-

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“With EN 12354-5, uniform calculation ↓ models for installation noises are During this planning stage, it can be determined how much structure-borne sound will eventually available for the first time. This is a major be transmitted from the sanitary walls to the building structure and how loud the sanitary noise step in the right direction.” in neighbouring rooms will be. Oliver Wolff Head of Building Physics Geberit Group

installed but only half-height GIS sanitary module with the same fittings. The sometimes significant - differ ences can largely be attributed to the different system configuration and connection technology.

THE DIFFERENCE FROM THE REALISTIC EXPERIMENT To now determine how much sound is transmitted from a certain sanitary installation to the building structure, the installation is measured acoustically in a test facility for reception plates. A facility like this has been built at the Building Technology and Acoustics Laboratory in Rapperswil-Jona (CH) according to the specifications laid out in the EN 15657 standard. This consists of three decoupled, homogeneous, 10-cm- thick concrete plates (one horizontal and two vertical). The plates are also decoupled from the floor and walls.

The installation elements and sanitary walls to be in- spected are professionally installed on and in front of these plates. The structure-borne sound that these elements transmit to the individual plates when in op- eration can then be determined. The results are used lation noises now also available with the EN 12354-5 afterwards as input data for digital calculation models. standard. These models work with input data that “The sound propagation values that are forecast by has been calculated using the reception plate method these models sometimes differ significantly from the (EN 15657), which is explored in more detail below. measuring results seen earlier when using the realistic test setup,” comments Oliver Wolff, Head of Building Each sanitary wall has its own acoustic characteris- Physics at Geberit International. “The reasons for this tics. A correctly installed floor-to-ceiling Geberit are varied. Therefore, in complex building projects in Duofix installation system with elements for the cis- particular it is important that the architects and sani- tern and washbasin that is connected to a floor drain- tary engineers not only rely on model calculations age system consisting of Silent-PP pipes, for example, when planning the layout of the sanitary installations, has different acoustic characteristics to a correctly but also on the expert knowledge of the manufacturer.”

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GEBERIT AQUACLEAN DESCALING MADE SIMPLE

1

6

5

2

4 3

↑ 1 Inlet for descaling agent The descaling agent is flushed through all water-bearing parts (highlighted here in blue). 2 Continuous flow heater 3 Water pump 4 Water tank 5 Turning valve 6 Spray unit

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The Geberit descaling agent can be ordered conveniently. Please feel free to contact us. is found in many places. Shower toilets contain pipes and parts whose functionality can be affected USEFUL INFORMATION if operated with hard water for long –– Descaling is required at least once a year. periods. For this reason, Geberit shower –– All water-bearing components are treated toilets are equipped with an automatic in the descaling programme. descaling programme. –– The Geberit AquaClean app is there to let the operator know when the next descal- ing is due. Lime – or to give its chemical name – can be found in a range of different rocks and –– All Geberit AquaClean models can be soils, where it is washed out by rainwater. In doing so, used without the spray functionality dur- the calcium carbonate reacts with the ing the descaling programme. dissolved in the water and forms highly soluble cal- –– The time required by the descaling pro- cium bicarbonate. The enriched water then reaches gramme varies depending on the model: the consumer via the waterworks as drinking water. If Mera = max. 60 minutes, Sela = max. 40 the drinking water is heated in the shower toilet, the minutes, Tuma = max. 30 minutes. soluble calcium bicarbonate decays to form insoluble calcium carbonate – or . This limescale set- –– In order to prevent damage to the device tles on all surfaces that come into contact with water caused by aggressive media, it is recom- and results in malfunctions over time. If a layer of mended to only use Geberit AquaClean limescale builds up on heated parts – such as the descaling agent. heater in the shower toilet – the transfer of heat from –– After filling with descaling agent, the des- the heater to the shower water is restricted. In the caling procedure should not be cancelled worst case, this can lead to faults on the heater. as the agent would then be flushed out without being used. AUTOMATIC DESCALING PROGRAMME In order to prevent damage to water-bearing com- ponents, the shower toilet has to be descaled regu- larly. For this reason, all Geberit AquaClean shower toilets are equipped with an automatic descaling pro- gramme. On all models, the control panel shows when descaling is necessary. After the descaling agent has been added by hand, the procedure can be started at the touch of a button. In the subsequent 30 to 60 min- utes, the descaling agent is fed through all water-bear- ing components such as the water tank, continuous flow heater and water pump. During the procedure, it reliably removes deposits from all components. Finally, the agent is flushed out together with the removed limescale. The descaling agent is safe for the environ- ment as the reaction of the agent with the limescale neutralises the contained within.

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document2259750206718713432.indd 17 08.11.2019 14:54:16 REFERENCES

↑ Anything but drab and boring – the bright facade of the children’s hospital immediately catches the eye.

NEW CHILDREN’S HOSPITAL, HELSINKI, FINLAND STATE OF THE ART MEDICAL CARE IN COLOUR- FUL SURROUNDINGS

The New Children’s Hospital in Helsinki opened in autumn 2018. The qualified personnel, state-of-the-art equipment and friendly atmosphere ensure first- class medical care for the young patients.

NEW CHILDREN’S HOSPITAL Building owner: New Children’s Hospital Foundation Architecture: SARC Architects Completed: June 2018 GEBERIT KNOW-HOW Duofix installation system Mapress and Mepla supply systems → IDO Seven D washbasins The appearance of the facade panels changes depending on the IDO Seven D WCs angle they are looked at.

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document3525582272186536594.indd 18 08.11.2019 14:54:19 ↑ The recreation rooms have an inviting, relaxing atmosphere and take visitors and patients alike on a journey to another world.

Opened in autumn 2018, the children’s hospital has a sinki University Hospital, specialises in the treatment wealth of child-friendly rooms and lots of colourful of heart diseases and various cancers as well as organ recreation spaces. The young patients enter a fantasy transplants. The young patients, who range from new- world stretching across eight storeys. The journey born babies right through to adolescents, are looked begins in the underground floor, which represents the after by a team of around 1,000 specialists and nurs- seabed, and continues up into the forest before end- ing staff, who have the latest infrastructure and tech- ing in outer space. Even from the outside, the new nologies at their disposal as well as direct access to building is anything but a drab concrete block. The the Helsinki University Hospital’s research institutes. building’s facade, which is adorned with numerous colourful slat-like elements, looks like a never-ending The sanitary facilities at the hospital – which also rainbow. feature Geberit products – are also impressive. The Duofix installation system is installed behind the wall, STATE-OF-THE-ART INFRASTRUCTURE to which the high-quality washbasins and WCs from Helsinki’s New Children’s Hospital cost around 170 the Finnish brand IDO are attached. million euros to build, almost 40 million of which came from donations. The 140-bed hospital centralises the treatment of children from across Finland and abroad. Furthermore, the institution, which belongs to the Hel-

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document3525582272186536594.indd 19 08.11.2019 14:54:24 Geberit Southern Africa (Pty.) Ltd. 6 Meadowview Lane Meadowview Business Estate Longmeadow, Linbro Park ZA-Johannesburg

Phone +27 11 444 50 70 [email protected]

www.geberit.co.za

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