GEA Refrigeration Technologies

GEA Refrigeration Technologies

Factory Tour: Production of GEA Bock compressors in Frickenhausen

engineering for a better world

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In Frickenhausen, GEA Bock compressors and condensing units for stationary and mobile refrigeration as well as for air conditioning are produced.

We offer the right compres-sor for refrigeration and air conditioning in all com-mercial, industrial, rail, bus and transport sectors. GEA Bock has been a com-pany of GEA Group Aktieng-esellschaft since 2011 and is part of the GEA Refrigeration Technologies segment. The Frickenhausen site is divid-ed into Administration, Training Center and Production. Prod-uct-related training courses take place in the Training Center. Thousands of GEA Bock com-pressors are manufactured annually in a production and warehousing facility with a total surface area of 8,600 m².

GEA Refrigeration Technologies

Administration

Production

Training Center

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FK vehicle compressors Lightweight, compact, robust and efficient vehicle compressors for mobile air conditioning and refrig-eration systems.

Classic applications: Bus air condi-tioning, rail air conditioning, trans-port refrigeration.

F open-type compressors Open type compressors for exter-nal drive (via V-belt or coupling). Classic applications: Marine sector (e.g. provision cooling, ship air con-ditioning).

Semi-hermetic compressors Suction gas-cooled semi-hermetic HG compressors and air-cooled semi-hermetic HA compressors. Also available as semi-hermetic condensing units (e.g. Plusbox out-door complete condensing unit). Classic applications: Supermarket refrigeration, commercial air condi-tioning, building technology.

Product range of GEA Bock compressors

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1932

1937

Founding of the company in Stuttgart by Wilhelm Bock and

Hans Göldner

Production for the first time of open refrigerating machines and

relocation to Nürtingen to a larger factory building

1955

1966Development and construction of automobile air conditioning

(installed in the VW Beetle)

1970 Expansion of the product range to vehicle compressors and larger

stationary compressors

1993Relocation of Administration to Frickenhausen

1994 Introduction of the semi-hermetic HA (hermetic

air-cooled) and HG (hermetic gas-cooled) series

1996Introduction of the FK40 vehicle compressor

2007

2011

2012

New Training Center

Bock becomes part of the GEA Group

New production hall and warehouse

History

Construction of a new subsidiary factory in Frickenhausen (initial production area of 1,000 m²)

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References

Leading manufacturers, such as MAN in the team bus of the soccer team

Borussia Dortmund, rely on GEA Bock FK compressprs for bus air

conditioning.

Semi-hermetic GEA Bock compres-sors are responsible for the reliable refrigeration of food and drinks in

restaurants - as here in the Sausalitos in Stuttgart.

GEA Bock compressors ensure that food and fresh produce is refrigera-ted in ideal conditions at countless

supermarkets (e.g. in the COOP supermarket in Birsfelden or in the

REWE branch in Fulda).

GEA Bock compressors ensure optimum provision cooling

on the high seas (e.g. on the cruise ship

AIDA Aura).

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Production

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Central Customer Service / Repair

Manufacturing

Measurement room

Presetting tools

Cleaning facility

Preparation of the compressor housing

Compressor assembly

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Test-bench

Paint shop

Electrical assembly

Assembly of the condensing units

Final assembly and dispatch

Goods-in inspection

Warehouse

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Station 1: Central Customer Service / Repair

- Inspection of the compressors

- Analyzing the cause of the breakdown

- Support / information on solving the problem

Factory Tour

Station 2: Manufacturing

- Setting up the blank housing ready for machining

- Machining and resetting of the blank housing (change of position)

- Checking functional dimensions in the manufacturing process (QA)

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Station 3: Measurement room

- Measuring the finished compressor housing for dimensional accuracy

- Checking all delivered parts on a sample basis by means of a test schedule

Factory Tour

Station 4: Presetting tools

- Measuring and adjusting tools for e.g. CNC centers

- Possible corrective actions are integrated into the manufacturing process

- Tool management: approx. 1000 tools are catalogued

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Station 5: Cleaning facility

- Cleaning of finished parts

- Cycle time: 6-7 minutes // washing temperature: 90°C

- Removal of grease, oil and machining chips

Factory Tour

Station 6: Preparation of the compressor housing

- Sight glasses

- Connection seals

- Cylinder roller bearings

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Station 7: Compressor assembly

- Assembly of the compressors

- Assembly of semi-hermetic compressors and vehicle compressors (2 production lines)

Factory Tour

Station 8: Test-bench

- Checking all compressors for hermetic integrity and any leaks

- Tests on the motor side and on the compressor side

- Different tests on FK compressors and semi-hermetic compressors

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Station 9: Paint shop

- Color application for the compressors

- Paint finish with 2-component RAL 5000 paint; special paint for ATEX compressors

Factory Tour

Station 10: Electrical assembly

- Electrical assembly of the compressors

- Installation of the motor protection (MP10)

- Installation of the terminal board connection and PTC thermistor

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Station 11: Assembly of condensing units (optional)

- Construction of a condensing unit with a previously tested compressor

- Final leak search (helium test)

- Assembly takes place in the new production hall

Station 12: Final assembly and dispatch

- Completion / final stage (e.g. adding of operating manuals)

- Dispatch of the compressors to the customers

Factory Tour

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Factory Tour

Station 14: Warehouse

- Barcode reader and EDP acquisition

- “First In First Out” // “Just In Time”

Station 13: Goods-in inspection

- Testing parts on a sample basis

- Testing by means of pre-established schedules / specifications

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GEA Bock India Pvt. Ltd.

Vadodara, India

Assembly

Approx. 65 % FK compressors, 35 % all the other compressors

GEA Bock Compressors (Hangzhou) Co., Ltd.

Hangzhou, China

Production and assembly

Primarily FK compressors

Other production sites

GEA Bock Czech s.r.o.

Stribro, Czech Republic

Production and assembly

Mainly semi-hermetic compressors

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values. Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA Refrigeration Technologies

GEA Bock GmbH

Benzstraße 7, D - 72636 FrickenhausenPhone: +49 7022 9454-0, Fax: +49 7022 9454-137bock@gea.com, www.bock.de, www.gea.com ©

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