"Roof technically up to date"

Innovative technologies, products in the premium segment, and tailored services connect MTU Aero Engines AG Munich with its service providers and suppliers. MTU is Germany's leading and only independent manufacturer of engine components and a global established entity. In spring 2013, the Blisk competence center was commissioned at the company headquarters in Munich. The new production hall 077 is enclosed externally by eight high-insulating rapid-action doors from EFAFLEX.

The high insulation level of the rapid-action doors was an important factor in choosing the doors. Also, the quick opening and closing speeds. "This hall is used to manufacture Blisks (Blade Integrated Disks). These are high-tech components that are machined from a single piece and are increasingly used in modern engine compressors," explains Maximilian Stärfl, project manager for new construction, responsible for planning and static calculations of the new hall. "To produce the Blisks, we need a constant temperature of 21 degrees Celsius plus-minus 0.5 degrees in the hall. Temperature fluctuations would lead to inaccuracies that we simply cannot afford in engine technology."

Measurement chambers integrated into the hall, where components are scanned with lasers for irregularities, are subject to a special temperature monitoring, as virtually no temperature differences should occur here. Perforated sheets in front of the windows let enough light into the hall, keeping unnecessary sunlight outside. The smoke extraction flaps in the hall roof also prevent direct sunlight from entering. An ventilation system, whose central unit on the hall roof is easily the size of three single-family homes, ensures a constant, draft-free ventilation of the manufacturing hall. Wide-throw nozzles gently distribute fresh air throughout the building. To prevent temperature differences when opening the exterior doors, the planners opted for door airlocks. After a vehicle enters, one door is first closed before the second door opens. This applies both to the direct access to the hall and to the airlocks for delivery and pickup of materials and products. The central lubrication system, where chips are filtered from the lubricant, is also separated from the hall by a door airlock.

The new Blisk manufacturing is considered the most modern worldwide for engine parts of this kind. The centerpiece of the optimized and automated process-based production concept is a 96-meter-long main distribution system. The system's master computer calculates the occupancy of all workstations in the hall and transports components to the individual machines.

Not only the manufacturing concept but also the planning and construction of hall 077 prioritized energy efficiency and economic viability. Well water cooling and heat recovery with a heat pump, along with state-of-the-art ventilation technology, ensure that the new building saves about two-thirds of energy costs compared to the old facility. "The Efaflex doors perfectly match the specifications and guidelines for exterior doors," emphasizes Maximilian Stärfl. The installation of doors from the specialist in rapid-action doors began sporadically about 15 years ago. "In the past five years, we have exclusively installed doors from Efaflex, which now account for about 80 percent of the entire plant. Sure, it could be cheaper. But the doors are technically the best impression, and Efaflex is the highest quality door supplier. Compared to other manufacturers, these doors have the fewest defects."

Trust in suppliers and service providers is indispensable for production at MTU Aero Engines AG. The company develops, manufactures, sells, and services engines of the highest quality, for both civilian and military aviation sectors, maintains, repairs, and supplies spare parts as needed. With such comprehensive expertise, MTU has consistently expanded its position as one of the market leaders in civil aircraft engines. Core competencies of the company, with its nearly eighty-year history, include the development and manufacturing of highly demanding components such as low-pressure turbines and high-pressure compressors, as well as innovative manufacturing and repair processes. These components are used in many passenger aircraft on short, medium, and long-haul routes.