Fully automated

The new 160 meters long Duofix line in Lichtenstein. (Photo)

Vertically, it is as high as the highest church tower: the new Duofix line in Lichtenstein (DE) is 160 metres long. Even more impressive is the Geberit know-how that facilitates fully automated operation.

It would be no problem to jog around the new Duofix WC production line. There would be no danger of oncoming passers-by. The production line is fully automated from start to finish. Thirty-two robots make sure that a Duofix frame leaves the production line every eight seconds.

The individual parts of the Duofix frame are created by profiling and punching. (Photo) — The individual parts of the Duofix frame are created by profiling and punching.

The individual parts are moved into the right position and prepared for welding. (Photo) — The individual parts are moved into the right position and prepared for welding.

The Duofix frame is cleaned, dried and receives its striking blue colour in the powder coating plant. (Photo) — The Duofix frame is cleaned, dried and receives its striking blue colour in the powder coating plant.

At the end of the line: the Duofix frames are stacked here ready for removal. (Photo) — At the end of the line: the Duofix frames are stacked here ready for removal.

The finished Duofix frame – the process is completed in Pfullendorf (DE) by attaching the cisterns. (Photo) — The finished Duofix frame – the process is completed in Pfullendorf (DE) by attaching the cisterns.

The new Duofix installation element (Photo)

The new Duofix element

All information on the new Duofix installation element with its numerous innovations can be found here.

Hungry for steel bands

The facility is fed with coils, giant rolled-up metal bands. Sixty tonnes are needed every day. In a first step, they are converted into the side profiles and crossbars of the Duofix frame by means of profiling and punching.

Hot phase

The different individual parts of the frame are then moved into the right position and prepared for welding. This is done in three cells, each with four welding robots. The technique used guarantees outstanding weld seam quality.

Washing, drying, coating

What sounds like a visit to the hairdresser is in fact a trip for the welded Duofix frame to the powder coating line. Suspended from brackets, the frames embark on a ghost-train-like ride. On the way, they are first cleaned and dried. And finally, powder coating gives them their striking blue colour.

And then add some feet

The Duofix frame is finished off in frame assembly – it is equipped with feet and extensions and then stacked for removal. An additional nine robots are in use for this purpose. The Duofix is now ready for its journey to the plant in Pfullendorf (DE) for further processing.