High-Speed Sustainable Warehouse Doors

Industrial doors from Efaflex lead the world because they combine premium manufacturing, super high-speed operation and exciting energy-saving opportunities, writes Paul Hamblin, Logistics Business Features Editor.

Efaflex builds and supplies some of the world’s fastest high-speed industrial doors for a wide range of settings – 16 sectors at the most recent count – and you know the German-founded company is confident of that speed because the company familiar logo carries the image of a cheetah, the world’s fastest land animal. That’s confidence.

Such confidence can often be misplaced, of course. The fact that Efaflex delivers on its promises is testament to the long-term global reach and reputation of the company. Even doors with a 10,000mm width can achieve a door leaf speed of 1 m/s. The company says its fastest vertically opening high-speed door is able to achieve top speeds of more than 4 m/s.

Technological and engineering excellence are core to the Efaflex success story. Unique spiral technology enables the door to be both faster and lighter than the competition, while safety is ensured by a myriad range of sensors, all supplied specifically to suit customer needs. “Our consultants can prescribe exactly what you as a customer require,” Head of Marketing Christian Jacob (pictured below) tells me. “There is an individual light and sensor grid inside every door we produce. It will integrate with the manual labour workforce or seamlessly integrate in a Smart warehouse setting incorporating AGVs and AMRs,” he adds.

All doors are manufactured at the company’s plant in the Czech Republic. The latest generation continues to push the boundaries. “It’s about more platform thinking in important areas such as spare parts and the interior of the door,” explains Jacob. “So, even if the shutters vary, each door will have the same framework, which facilitates spare parts efficiency as well as overall maintenance. The beauty is all on the inside, if you like.”

Enabling Customer Sustainability

A central focus of the company’s ethos is to assist in the sustainability efforts of its customers. “We do that by ensuring we provide the door which best saves customer energy consumption,” he reveals. “We start that process directly with the customer, establishing what matters to them so that we can then add to their sustainability story. This is about starting from the customer’s perspective.”

Christian Jacob, Efaflex

Efaflex has introduced EFA-EnergySaver, an easy-to-use tool available to all visitors to its website. Applicable by use case – workshop, production facility or warehouse – in a few clicks you can gain a detailed comparison of potential energy savings via scrutiny of such details as door size and dimensions, door speed, number of doors, opening cycles per day, productive days per year and heating/cooling costs.

All Efaflex doors are high-speed, whether spiral, roll-up or folding, or a clean room or machine protection door. How do customers know which type should be selected, though? “It depends on the hole in the wall and where it is,” he laughs, before elaborating, “You won’t have a fabric door in an outdoor-setting, for instance.”

He won’t reveal how many doors Efaflex installs per year across the globe, other than to quote a figure “in the thousands”. This is fair enough: Efaflex remains a family-owned business and is under no obligation to quote such figures.

Jacob is in broad agreement with the current sentiments around wider market uncertainty, but counters that Efaflex’s order book is “vivid”, adding that sectoral ups and downs are part of business. “We supply 16 different verticals,” he adds. “In these 16, one will always be under pressure; at the moment, automotive is a good example of that, so two current strong points for us, for instance, are in food and in supplying doors for public parking security in urban environments.”

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Zip Technology for High Speed Doors

A new flexible, high-speed door has been launched by Hörmann UK which helps reduce downtime caused by damage and is quick to install. The V 5025 Z door is fitted with innovative zip technology and in the event of a collision the door curtain pulls away from the side rail to prevent damage. It is then automatically re-fed into the rail restoring the door curtain to its original position and operation.

The robust construction of the V 5025 Z door make them suitable for both internal and external installation. Manufactured from high quality PVC they are certified to DIN EN 12424-1, with Class 3 wind load resistance, Class 1 air permeability and Class 2 resistance to water penetration. With an opening speed of 2 m/second V 5025 Z doors help to optimise traffic flow and save energy. Their large, clear vision panels also enhance operator safety and help increase light in the working environment. Additional protection is provided by the safety light curtain which is included as standard.

Installation of the V 5025 Z is quick and straight forward with compact fitting dimensions and extensive pre-assembly, with Hörmann‘s unique SNAP cable concept making it easy to connect. Transport is easy and cost effective as the V 5025 high-speed door is delivered with the drive unit, control, and accessories in a single box. The Hörmann BK FU Z control is included as standard.

Doors can be supplied up to a maximum size of 5000mm x 5000mm, and offer an attractive price-performance ratio, impressive service life and have been designed to be low maintenance. The V 5025 Z flexible door can be used in a combination with Hörmann sectional doors, roller shutters and spiral doors, and are suitable for either new build or retrofit installation. They are also available CO2 neutral as an option.

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Lower Energy Costs thanks to High-speed Doors

Jihostroj, the biggest Czech manufacturer of hydraulic systems and aircraft instruments, saves 35 percent of its energy by installing EFAFLEX high-speed doors. Where high-quality components and assemblies for aircraft engines are manufactured, it’s all about absolute precision. And, at Jihostroj Aero Technology and Hydraulics in Velešín in the Czech Republic, this accuracy begins with constant temperatures in the production area. This allows them to guarantee that the materials to be processed are not subject to any temperature fluctuations, which requires high energy expenditure. To keep costs at an affordable level in times of extreme price increases for electricity and heat, the company concentrated on a concept for saving energy. Part of the implementation of this project consisted of installing eight high-speed doors from EFAFLEX at the production hall in Velešín.

“All companies have to react to rapidly increasing energy costs. That’s why we decided to renovate the existing production hall. The building façade was insulated and EFAFLEX high-speed doors were installed at the entrances. We already had many years of positive experiences with these doors in other operations within our company,” says Jan Kříha from Jihostroj. “The renovation has paid off: the energy savings have surpassed our expectations – our costs are now 35 percent lower. And the sophisticated design of the doors provides added value.”

New cost-cutting concept: insulation and fast doors

Components for the aviation industry are manufactured in the production hall in Velešín. The production hall gained 12 centimetres of insulations, new cladding, and the roof was recovered. The access points to the hall have also been transformed: they used to just have normal metal doors through which the equipment was transported, and the employees could access the hall. That changed during the renovation. Alongside the newly fitted staff entrances, four insulated EFAFLEX EFA-SST® high-speed doors were installed in the building. Openings in the building could be reduced to what it actually required thanks to installation of the new doors. Creating separate entrances for the employees now also improves occupational safety because routes for people and vehicles are separated from one another. The unnecessary manual opening and closing of the door is also now a thing of the past.

Durable and fast

The high opening and closing speeds, reaching up to 2.5 m/s, play a major role in saving energy – the quicker the doors open and close, the less heat escapes from the hall. Therefore having economic benefits and also a significantly longer service life in comparison with sectional doors. Their 250,000 cycles per year correspond to hundreds of openings per day.

Better working environment and faster logistics

And it’s not just the energy saving that the responsible parties are satisfied with following the renovation. Restructuring of the interiors and installation of four EFA-STR®-L high-speed doors has improved working conditions for the employees. Because the rapid opening and closing of the doors in the interior spaces reduces drafts and thus improves comfort in the workplace. Logistic processes run smoother now as well.

Induction loops for improved occupational safety

In addition to savings, consideration was given to improving safety with the renovation. Along with the installation of separate staff entrances, induction loops were therefore also installed in front of the high-speed doors. They are fitted in the floor in front of the doors and guarantee that the doors only open when the transport vehicle drives into or out of the hall. They do not react to normal traffic in front of or behind the door and thus prevent unnecessary opening.

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High-speed Doors for Production

For almost 40 years, more and more high-speed doors from Efaflex have been reliably doing their job in the production of Wernsing Feinkost GmbH in Addrup-Essen/Oldenburg, Germany. And in all these years, both companies have worked with many ideas and in partnership to ensure that the installation of a door has become a success story with a future.

The production halls of Wernsing Feinkost GmbH are as dynamic as the relationship between the two business partners. Employees ensure that the pallets with packaged goods are directed to the correct transport routes. In other rooms, they carefully monitor seemingly endless production lines on which the deli salads are produced and packaged, which we soon be found on the supermarket shelves. Each production area is separated from the other by an EFAFLEX high-speed door. Today, more than 200 EFAFLEX high-speed doors are installed at the most varied of locations in the huge Wernsing Feinkost GmbH plant. In the course of their time together, what used to be a small food company from Addrup-Essen in Oldenburg has grown into a huge company that is now one of the most important employers in the region and in other areas of Germany.

At the same time, EFAFLEX has developed into a specialist and premium provider for high-speed industrial doors and exciting industry solutions. The application variants of the doors in the Wernsing Feinkost GmbH plant are correspondingly diverse: “They are designed for high loads and can therefore be found in almost all production-related areas. They are also perfect for separating automated areas,” explains Patrick Wehage. He is as Deputy Team Leader for Technology, responsible for the maintenance of all logistical areas in the plant. The EFA-SRT-MS Machine Protection doors, for example, ensure that employees are not injured on the transport routes. High-speed roller doors EFA-SRT separate different production areas from each other.
In addition to the possibility of integration into smart logistics processes and the resilience of the doors, the planners at Wernsing Feinkost GmbH as a food manufacturer also considered the tightness and pressure stability of the curtains to be important.

Conveyor technology controls door movements

Compared to other areas of the plant, it is relatively quiet in the new deep-freeze high-bay warehouse. Gondolas packed with goods glide quietly on ceiling rails through an alley to various doors. They pause for a moment in front of the Machine Protection doors, which open immediately. The pallets are then transported on roller conveyors to the locks in front of the deep-freeze warehouse.
“As in other areas of our plant, the conveyor technology and driverless transport systems control the doors here,” Patrick Wehage emphasizes a special feature of the EFAFLEX door control and immediately adds: “This deep-freeze high-bay warehouse is inerted. For EFAFLEX, for reasons of fire and explosion protection, this meant that every cable had to be routed into the warehouse in cable ducts.”

The doors on the logistics routes in the plant open up to three times a minute, i.e. 180 times an hour. “Due to their gentle movements, they don’t suffer a great deal of wear and tear. This is simply robust technology that even a layman can handle well,” says Patrick Wehage, who describes himself as an enthusiastic mechanical engineer. “Spare parts come quickly when needed. This is particularly important for our chilled areas.” Doors from other manufacturers? “Never change a running system. It works perfectly, period!”  A good sign for the future: the joint success story can continue.

Protection for man and machine

Thanks to their space-saving, self-contained design, the Machine Protection doors from EFAFLEX can be perfectly integrated into the required protective equipment. They stand out due to their extraordinary resilience and stability. The standard door leaf of the EFA-SRT-MS is fully transparent and comes with warning strips as standard. Colored, highly tear-resistant and laterally stable hangings are also readily available. All curtain variants are free of paint-wetting-impairing substances. The interaction of a powerful frequency converter control and a functionally adapted drive enables the very high cycle rate of up to seven cycles per minute in production processes. The doors are constructed in such a way that a weight compensation mechanism is not necessary, which allows for a narrow design of the side frames. This significantly reduces the amount of maintenance and wear and tear. A transparent cover offers a clear view of the integrated safety limit switch of Cat. 4 / Pl according to DIN EN ISO 13849-1. With the optional floor supports, the protective devices can be set up free-standing. Uneven floors are compensated by leveling screws.

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Giant Doors for a Stable Climate

It is among the most cutting-edge in the world: the new company site for cross-laminated timber (CLT) in Ždírec, Czech Republic, was inaugurated in October last year. The new production line makes an essential contribution to STORA ENSO’s growth strategy in the timber construction solutions sector. The annual production capacity is around 120,000 m³. This modern complex, costing 80 million euros, now includes 22 EFAFLEX high-speed doors. Doors from the premium manufacturer EFAFLEX are also in use in Planá in Western Bohemia and Ostrava, two other sites in the Czech Republic associated with the brand.

“Our company is dedicated to products based on timber and biomass. It is therefore important to us that our customers and suppliers are also looking for environmentally friendly solutions. EFAFLEX doors fit perfectly into this spectrum thanks to their speed, reliability and long service life. The benefit of these doors is that they meet all the specified requirements, even for over-size products,” explains Tomáš Adamec, technical manager at STORA ENSO.

High-speed doors from EFAFLEX are designed for industrial use. They meet the high requirements demanded by modern operations, are reliable, and can save a significant amount of energy thanks to their high opening and closing speed. “Another factor that is just as important is that fast-closing doors contribute to a stable climate at the workstation. That creates more pleasant working conditions for the employees in the halls,” Tomáš Adamec describes further benefits of the doors.

High-speed doors for the lorry entrance

EFAFLEX has installed very high and wide doors at the Ždírec factory in order to allow large lorries to enter. That’s why three EFA-SST®-XL Premium with respectable dimensions of almost 9 metres in width and 5.5 metres in height were chosen. The fact that the doors are designed as external doors for halls and have good insulation is crucial, because the savings depend not only on the opening and closing speed, but also on the size of the doors to be opened. The larger the opening for the airflow, the more important it is to close it again quickly so that the area around the door does not cool unnecessarily.

High-speed doors on the upper floor

But high-speed doors with large dimensions are not the only interesting applications at the STORA ENSO factory in Ždírec. Three further high-speed doors on the upper floor level, EFA-SST®-L ECO, are used by forklifts to bring the material to the upper floor. The doors each have dimensions of 3 x 3 metres, there are insulated, and they have an opening speed of up to 1.5 m/s. They can handle up to 200,000 load cycles per year. 21 of the doors in Ždírec are external doors with an insulated design. An interior door, the EFA-STR®-S, is used to separate interior areas.

For safety and easy operation

In addition to the industrial doors, EFAFLEX offers a comprehensive range of safety accessories and thus guarantees that logistics go smoothly. These include the EFA-TLG® infrared light curtain, which is integrated directly into the door closing line, for example. Intersecting infrared rays create a flat light grid which can detect even the smallest obstacles without contact. If something is in the way, the closing movement stops immediately or is not initiated in the first place. This protects people, doors and transport equipment.

STORA ENSO – a sustainable manufacturer with products made from renewable raw material

Ždírec is the fourth STORA ENSO CLT factory after Bad St. Leonhard and Ybbs in Austria and Gruvön in Sweden. As a leading provider of renewable products in the packaging, biomaterials and timber construction sector, the company is also one of the largest private forest owners in the world. The STORA ENSO Wood Products division is the largest sawn timber producer in Europe and one of the leading providers of sustainable timber-based solutions for the global construction industry. Sustainability is an integral part of the STORA ENSO business strategy.

The growing Building Solutions division offers building concepts and a comprehensive range of products to support low-carbon construction. The employees develop services and digital tools to simplify the planning and construction of buildings with timber. The company has around 21,000 employees and its turnover in 2022 was 11.7 billion euros.

High-Speed Roller Doors

A roller doors case study from the world of manufacturing offers useful pointers in upgrading legacy warehouses that run fast-moving logistics scenarios.

Established 30 years ago in the buildings of a former concrete factory, Telford-based Hager UK Limited has transformed the site into a high-calibre modern manufacturing base. It is a leading provider of solutions and services for electrical installation in residential, commercial, and industrial building, with products ranging from power distribution, cable management and cabling accessories to building automation and security systems.

As the company grew, so the buildings needed to be modernised. The internal doors were also gradually replaced, but this did not bring the desired results. For this reason, the factory planners decided to assess an EFA-STT® high-speed spiral door from Efaflex.

The first door was installed in 2020, intended as a test to replace and upgrade the old roller doors at the factory. The test was an undoubted success. In addition to opening speeds of up to 3 m/s, the door offers maximum wind resistance and can be supplied in standard sizes of up to 8,000 mm in width to 7,800 mm in height.

Plenty of daylight

Thanks to slats made of crystal-clear acrylic glass, the door leaf of the EFA-STT® is more than 70 percent transparent and allows plenty of daylight into the production areas. The unobstructed view through the door brings decisive advantages: accidents are avoided, and smooth transport processes are guaranteed.

The door leaf of the EFA-STT® is kept at a distance in a spiral. Thanks to contact-free winding, the transparent slats remain virtually wear-free and ensure a clear view for years to come. Due to the individual design of the slats, the EFA-STT® can be adapted to the desired application. All visible sections of the door are made of PVC-free acrylic glass as standard. Any combination with grey coloured slats is also possible on request. A translucent lamella look is also optional. This allows full incidence of light and at the same time protects against prying eyes.

More orders announced

For Hager UK, the EFA-STT® was equipped with the EFA-TLG® door light grid, which monitors the closing level of the door up to a height of 2.5 metres. Infrared rays create an almost flat light grid that can detect even the smallest obstacles without contact and, in this case, stops the door movement immediately. The door light curtain was integrated into the factory’s existing safety equipment.
In 2021, due to the favourable experience with the first door, another was ordered from Efaflex UK. A heavily worn high-speed door with a textile curtain was to be replaced. For this application, the planners opted for an EFA-SST®-S high-speed spiral door. Thanks to the efficiency of the Efaflex technicians, the old door could be replaced and the new one handed over ready for operation within two days. Hager UK has also announced that it will order further systems for the exchange of old doors from Efaflex in the coming years.

24/7 Endurance Doors

A Bavarian body component manufacturer has installed doors which close at 1.8m per second, every 30 seconds, 24 hours a day, 7 days a week.

The EFA-SRT® MS machine protection doors from Efaflex open and close at a speed of up to 1.8 metres per second every 30 seconds, 24 hours a day, seven days a week at the new WMU
Bavaria GmbH plant in the town of Niederaichbach, Bavaria, to be fully reorganised under robotic lines by 2022.

Efaflex, the world market leader in the field of industrial high-speed doors, has developed door systems that are not only equipped with all conceivable safety features but can also be used as
EC type-examined safety components as per Machinery Directive 2006 / 42 / EC. Automotive component specialist WMU Bavaria benefited from this development when setting up the new plant. With 18 doors having successfully passed their two-month continuous load test, WMU Bavaria ordered 22 more machine protection doors. A total of 40 door systems have now been in operation to protect employees since the beginning of April. Many of the EFA-SRT® MS are equipped with a flame-retardant door hanging and an optional UV protection window for special application in front of the welding cabins.

Due to their space-saving, self-contained design, the machine protection doors from Efaflex can be adapted perfectly to the required protective devices. They stand out due to their extraordinary resilience and stability. The standard EFA-SRT® MS door leaf is fully transparent and equipped with warning strips as standard. Coloured, highly tear-resistant and transversely stable curtains are also available without any problems. All curtain versions are free from substances that interfere with the lacquering process.

The interplay between a high performance frequency inverter controller and a functionally adapted drive makes the high cycle rate of up to seven cycles per minute possible in production processes. Because of the lack of a weight counter-balance mechanism, the side frames are very slim; thus, the maintenance work and spare parts required are reduced significantly. The doors are designed for 250,000 load cycles per year.

A transparent cover provides a clear view of the integrated safety end-limit switch of cat. 4 / Pl »e« according to DIN EN ISO 13849-1. Thanks to optional floor supports, the safety devices can be installed as a stand-alone system. Uneven ground is compensated by levelling screws. Like almost all products from the world market leader, these door systems can also be perfectly integrated into fully automated processes and highly intelligent systems, which does, however, also require great flexibility on the part of the manufacturer for assembly: the machine protection doors were installed between Friday evening and Sunday, i.e. outside production times, to ensure that production could run smoothly during the week.

Efaflex designs, manufactures, installs and services high-speed doors for industrial and commercial applications. Founded in 1974, the company supplies to clients including food processing, manufacturing, clean room, cold store and the chemical, pharmaceutical sectors. As the only manufacturer of high-speed industrial doors, Efaflex has been entered into the world market leader index and is one of the 461 top companies in Germany, Austria and Switzerland. The privately-owned company has more than 1,200 employees worldwide.

Superfast all-Rounder Door

DMG Mori is a worldwide leading manufacturer of machine tools with a turnover of more than €2.6 billion. A total of 12,000 employees, suppliers and strong, reliable partners offer strong evidence of its success. Efaflex has supplied high-speed doors for efficient plant logistics to the Seebach site in Thuringia. “We have only been installing Efaflex doors for four years now,” reports Jörg Berz, head of plant technology at DMG Mori in Seebach. “The planners focused most attention on the very fast opening and closing speed of the EFASST and EFA-STT high-speed doors. Efaflex doors are the best there is. We have tested products from various manufacturers. Since we have had the fast doors from Efaflex, there is hardly any damage caused by forklift trucks.”

Maintenance and repair costs are also extremely low, which is why all older doors in the factory are gradually being replaced by those from the specialist for high-speed industrial doors. “The appearance of the doors is also very impressive,” says Berz. At DMG Mori in Seebach, the colour of the exterior doors has been adapted to the company’s corporate identity in the RAL colour iron grey. In addition to the standard aluminium-coloured coating, the manufacturer also paints the door’s laths and steel parts in almost any colour from the RAL system on request. As a result, the EFA-SST can be perfectly adapted to any façade to suit the architecture and customer specifications.

Superfast door

Both door types, the EFA-SST and the EFA-STT, can handle up to 250,000 load cycles per year: a must for the busy main logistics area at DMG Mori in Seebach. The doors perform the function of access control in other areas of the plant, such as the warehouse. They are opened here using a card reader. “This is very important for us,” explains Berz. “As a well-known shipper, we are
certified as part of the secure supply chain, for example for air freight, and must therefore meet high security standards. This means that only certain employees who have been checked for
reliability by the authorities may enter these areas.”

Read the whole article from our September issue here: https://flickread.com/edition/html/index.php?pdf=5f3d1fcf3160d#22

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