For more than 3 decades the Bremen-based SIKORA AG has been setting standards with innovative measuring and control devices for application in insulating and jacketing lines as well as in hose and tube extrusion lines worldwide.

In 1972 Harald Sikora presented the first non-contact measuring systems for energy cables and made the newly founded company a global player in the segment of measuring technology. The scope of supply mainly focuses on non-contact ovality, eccentricity and wall thickness measurement by means of X-ray radiation and optical diameter measurement on the basis of laser technology. “I am very happy and honored to receive this wonderful award, but it also goes to all who have significantly contributed to the success of our company“, says Harald Sikora.

Today, SIKORA AG has 128 employees at its headquarters in Bremen. Moreover, 40 employees at nine international offices and more than 30 regional representatives guarantee a flexible customer service on site. SIKORA had a fast-paced development of its turnover. Comparing the years 2003 to 2008 the company had a growth in the consolidated turnover from 9 million euro to 31 million euro. This success is in particular based on effective research and development of new products in Bremen and the focus of all activities to the demand of the customer.

Conventional methods to measure the melt temperature, such as contact thermocouple sensors, influence the melt flow properties which may result in early crosslinking. Other disadvantages of contact measurements are slow response times and inaccuracies of the measurement as a result of frictional heat. ULTRATEMP 6000* is a non-contact melt temperature measurement system based on non-invasive ultrasonic technology. It precisely measures the melt temperature during production and does not influence the melt flow properties. Therefore, melt shear heating effects do not occur. The ULTRATEMP 6000* determines the melt homogeneity and thus ensures homogeneous melt viscosity for the extrusion process. Early cross-linking after screens, which may lead to ambers and scorches in the polyethylene material is avoided. The ULTRATEMP 6000* includes an adapter, which is positioned in the flow channel between the extruder screw and the extruder head. The adapter consists of high-temperature ultrasonic sensors, i.e. an ultrasonic transmitter on one side and an ultrasonic receiver on the opposite side of the flow channel. The ultrasonic signal is sent through the complete cross section of the plastic melt flow to the receiver and the melt temperature is instantaneously defined in real time. The extremely high measuring rate allows a fast response time as well as the precise capture of small temperature variations.

ULTRATEMP 6000* can be combined with the display and control systems ECOCONTROL 600, 1000 and 2000 ensuring an efficient production control. The processor systems display numeric and graphical process information along with analysis tools as trending and statistical process control analysis. The ECOCONTROL models offer continuous monitoring of the measured values. Alternatively, ULTRATEMP 6000* can be delivered with a Profibus-DP interface. SIKORA’s temperature measurement system optimizes running time and productivity of the extrusion line and supplies an important step for further process optimization and costs reduction.

* Patent pending

There are alternatives to the worst-case scenario. Possible measures are for example the reduction of overtime and extra work, strategic vacation planning, setting up short time work, and partial retirement. Another option is the elaborate use of technical possibilities of latest developments in order to reduce the further big cost share besides personnel costs, the material costs during the production of wires and cables, hoses and tubes. By means of true cost calculations, the benefit of technologies, which increase quality and productivity during production, to the company’s balance sheet can clearly be defined. The following example will show that: “The integration of the eccentricity, wall thickness, ovality and diameter measuring system, X-RAY 2000, achieves more costs savings than the dismissal of five employees”.

While at the dismissal of employees usually compensation has to be paid, which will negatively influence the balance of the current business year as extraordinary costs, in case of an investment to reduce material consumption, only the linear depreciation values are shown in the balance sheet. In comparison, a compensation payment for dismissed employees adds up to an amount of 5 x 14.000 € = 70.000 € for five laid-off people². This would be similar to the investment in the measuring and control system X-RAY 2000.

At the beginning both measures, the investment and the personnel reductions, will influence the cash flow and the liquidity of the company in the same way, but in case of an investment, a credit for financing the project does much less influence the liquidity of the company as the following sample calculation shows.

Interdependency between material savings, profit and increased productivity
Assuming that at present the wall thickness of the product has a nominal value of 2 mm, but an average wall of 2.10 mm is applied, a material over-consumption of 5 % is achieved. Based on 6,600 production hours per year (3 shift operation) with a material output of 600 kg/h of the extruder and a material price of 1 €/kg, the material consumption is calculated by 3.96 million €/annum.

The reduction of the wall thickness by 0.1 mm (5 %) results in material savings of 198,000 €/per annum, which corresponds to 30 €/h. In consideration of costs for maintenance and servicing in the amount of 0.5 €/h and a depreciation of 1.32 €/h (depreciation, i.e. the reduction in the value of an asset, over 8 years, 6,600 h/year) the profit of the company improves from the first day of initial operation by 28.18 €/h. If this is multiplied by the assumed 6,600 h/year the impressive profit for one business year would be 185,988 €, by implementing an X-RAY 2000 in the production process.

In addition, proportional to the reduced material consumption the line speed can be increased, i.e. according to the above mentioned calculation a product surplus of 5 % will be produced on the line within the same time. On the base of an hourly rate for the machines of 100 €³ the savings resulting from the increase in productivity (0.05 x 6,600h/annum x 100 €/h) will amount to further 33,000 €/per annum.

Impact of personnel reduction on the performance of the company
In contrast, the lay-off of five employees would save labor cost plus payroll fringe costs to an amount of 250,000 €/annum (5 x 50,000 €). However, the saved labor and payroll fringe costs cannot be calculated in full amount as cost reduction. The available manpower is reduced by the laid-off employees and important know-how will be lost. Losses in quality have to be expected, as well as overtime work for the remaining employees, maybe with additional costs for payable overtime work and costs for subcontracted workers and outsourcing orders to other companies.

Once the business situation improves and the demand increases, new employees would have to be hired, which then requires cost intensive training as well. In an estimated calculation, only 50 % of the saved labor and payroll fringe costs can be assumed as cost reduction, meaning only 125,000 €/annum.

According to the previous example, the integration of an X-RAY 2000 in an extrusion line is in comparison to the dismissal of five employees evidently the more economic and more human solution. Even if with the measuring and control technology material savings of only 4 % would be achieved this statement remains, considering that only 50 % of the saved labor costs plus the payroll fringe costs will reduce the actual costs effectively.

Alternatives to personnel reductions strengthen the company
During the 36-years-old company history, the management of the Bremen/Germany based-SIKORA AG has recognized that the financial success of a company depends besides technical innovation on “soft” factors of the company culture. An employee-orientated management style and the connected commitment of the employees decisively contribute to the economic success.

X-RAY 2000 technology safeguards jobs
Within this company philosophy SIKORA has developed the X-RAY 2000 for online measuring and control of wall thickness, eccentricity, the diameter as well as ovality in production and extrusion lines to improve quality and efficiency in order to save costs. For this method of quality control the product is transilluminated by X-rays. Measuring values are continuously available within fractions of a second, which allows a fast centering of the crosshead and a continuous measurement and control of the extrusion line in consideration of the minimum values. The measuring axes are arranged under 0, 90, 180 and 270° position. The measuring values of the X-RAY 2000, i.e. diameter, ovality, wall thickness and eccentricity are displayed numerically and graphically on the processor system ECOCONTROL 2000. Not only in times of a booming business there is a demand for measuring and control equipment with the initial supply with new lines, but especially in times of depressed economy for productivity increase of existing lines. This is because nobody can on a long term afford to produce with excessive expense.

Conclusion
For sure, different approaches will lead a company to different results. Costs saving actions are always to be decided according to company liquidity, structure as well as economical and environmental circumstances. The implementation of measuring and control technology turns out to be an effective means to save costs, increase efficiency and at the same time to safeguard jobs. In addition to the introductory statement of the essay, for Harry Prunk it is obvious: “Know-how has to stay in the company – even more in times of crisis. Instead of permanently educating new employees, we enjoy the more efficient way: we are developing the individual. This offers for the team bigger chances to move the business forward from which customers benefit. We have many employees who have been with SIKORA for 10, 20 and even more than 25 years. Employee turnover is almost non existent, which keeps know-how in the company.”

²Depends on number of seniority, statutory provisions of the state

³Assumed operation costs for extrusion lines

In January 2009 SIKORA AG releases their new advertisement campaign, an innovative brand image. In cooperation with the agency for brand communication ”red pepper” SIKORA has developed an advertisement campaign with expressive pictures and an exceptional picture style.

For more than 30 years the Bremen-based technology venture stood for innovation, brand awareness and cost reduction in the segment of measuring and control technology. These brand values are the theme of the new campaign. The ad message communicates the added value, which SIKORA offers with its products: More quality, more productivity and more cost savings for production lines.

The main element of the campaign under the motto “SIKORA shows face” is an advertisement tag line, which is unique for the medium-sized company. SIKORA employees from different fields of work talk about product features and customer benefit. “The campaign expresses our strategic approach of an integrated communication. It personally addresses our customers and simultaneously conveys information about our products. With the advertisement message we turn our company philosophy into a picture. Our employees clearly stand by SIKORA products, which they communicate,“ explains Katja Beyer, Corporate Communications SIKORA AG.

The SIKORA AG, manufacturer of innovative measuring and control technology for the wire and cable industry ranks 18th among the 100 future medium-sized world market leaders in Germany, as determined by Berlin economy professor Bernd Venohr. Under the title “Exclusive ranking of the fastest growing medium-sized companies – Germans upcoming world champions“ Prof. Venohr made the evaluation for the Handelsblatt, Handelsblatt.com and Wiwo.de.

The nomination of the 100 fastest growing German world market leaderships resulted from a comprehensive data base. The following criteria were used for the selection: The Company belongs worldwide to the top three or is leading in Europe. The turnover was below 50 Mio. Euro in 2005 and has increased by at least ten percent annually in the last 3 years. The companies had no influence on the analysis and the result. SIKORA AG thus joins the top league of the classic medium-sized companies.

Sources:

http://www.handelsblatt.com/unternehmen/strategie-wachstum/deutschlands-kommende-weltmeister;2070919;0

http://www.handelsblatt.com/homepage/weltmeister/#18

Since 1995 SIKORA has been successfully collaborating with the representative S.O.C.E. OXYCOM in France, which is directed by Mr. Gérard Fraenkel, and has been able to develop a broad customer base in recent years. The manufacturer of measuring and control devices for the wire, cable, hose and tube sector continues its company strategy of nationwide presence and customer proximity with the new service base, which is also located in the building of S.O.C.E.. The SIKORA strategy is based on the setting up of service offices worldwide, which specifically cater to customer needs and ensure fast support and service on site.

“France is an important market for us, as many cable manufacturers in the branches of communication, automotive, energy, and installation have their base there. In particular in the hose and tube segment we aim to further strengthen our presence and to convince customers of our first-class measuring and control systems”, says Harry Prunk, Chairman of SIKORA AG. “With a service office on site and the representative S.O.C.E. OXYCOM we can service our customers even more intensively and further expand our market position in France”, concludes Prunk.

SIKORA has been working very successfully with the International Trade Consultancy (ITC) since July 1997 and follows the extremely positive business development in the Turkish market with setting up its own office. “We are proud to announce the forthcoming opening of a further office in Turkey”, says Harry Prunk, Chairman of SIKORA AG. “What is crucial is the closeness to customers and the further expansion of our sales activities in and around Istanbul. We see strong growth potential in particular in the East European an Asian region, which we want to generate for our measuring and control devices solutions”, explains Prunk further.

Head of the SIKORA office in Istanbul is Ajda Sariguelle. After an intensive 6-months training in Bremen, Mrs. Sariguelle, who has great experience in the field of administration and sales, will move to the new office at the end of this year.

No chance for contamination
The innovative camera system CSS 2 detects contamination particles of different size and concentration in XLPE-materials. Contamination can be specifically caused by material handling such as shavings, which are created by wear of the extruder screw. Moreover, the cleaning of the extruder screw leaves dust particles, which bring tiny pores or inclusions into the material. Not to forget contamination in the form of combustion particles such as amber and scorches, which occur during the long-term operation of the line. Contamination in the PE-material creates a considerable risk of breakdown. The CSS 2 eliminates this risk - for higher cleanliness and safety at the production line.

Objective process control and quality assurance
Compared to time-delayed laboratory analysis distant from the production line, the CSS 2 system ensures continuous real-time and online quality assurance. The intelligent system inspects 100% the XLPE-melt for purity in the flow channel and allows an immediate intervention in the production process. The flow channel between the extruder and the cross head includes sight glasses and an optical CCD-camera system which transilluminates the insulation material. The high-resolution CCD-color camera detects particles of 20 µm (0.79 mil) in the PE-melt. The identified constituents are classified with regard to their size. Particles, which exceed the specified tolerance value are analysed by the CSS 2 with highest precision. The particles are displayed graphically with regard to color in its surrounding as well as the vertical and horizontal dimension and the light absorption. Measuring data about contamination are registered on a hard disk for subsequent inspections. Besides the graphical display of the detected particles and its surrounding, monitor pictures show the complete material flow (live image) - even if the selected tolerance level is not exceeded – and a trend curve on the particles per liter. After data analysis the results are presented in a histogram according to size and quantity. With the help of this information the production process becomes superfluous with regard to an optimum material cleanliness. Easily, quickly and precisely the system informs the operator when he can start the production and shows when contaminations exceed the tolerance value and the operator has to intervene in the production process. In contrast to the mere granulate control the system actually detects contamination in the material before the cable is produced. Thus, the CSS 2 concept presents itself as an extremely powerful and efficient partner in the high-voltage cable production.

The opening of the service office follows SIKORA’s strong business performance at present and reflects the progressing expansion and continuing global operations of the SIKORA AG in the future.

The long-term successful partnership between SIKORA AG and its Egyptian representative HEAVY INDUSTRIES SERVICES CO. (HISCO) formed the basis for the assignment of a professional SIKORA service team on site. The new service office, which is based at the existing HISCO office will provide on-call technical service support to further improve customer satisfaction and to strengthen SIKORA’s presence in the Arabian countries. "Cairo represents an optimum location for our service office," says Harry Prunk, chairman of the SIKORA AG. “The intensive collaboration with our representative HISCO in Egypt during the last years has proven successful. The new service location allows us to offer improved service and responsiveness to the growing demands of our Arabian customers”, concludes Prunk further. The SIKORA service team in Egypt is now available at:

SIKORA SERVICE EGYPT
HEAVY INDUSTRIES SERVICES CO. (HISCO)
Mr. Karim El-Nahas
Building 15 Block 1149
Sheraton Heliopolis
Cairo/Egypt
Phone: +202-22672479
Mobile: +20100694343
Fax: +202-22672478
E-Mail: service@sikora-egypt.com
Internet: www.sikora.net

“I thank you very much for your trust and I am looking forward to the challenges in my new function”, commented the Bremen-born Sikora on his appointment. “Our aim is to continue our strategy of expansion and the long lasting development of our company to remain competitive”, says Sikora.

Since the change of SIKORA GmbH into a corporation in 2002, Prof. Dr.-Ing. Thomas Sikora as well as Wolfgang van Hettinga and Martin Siemer have been on the Supervisory Board of the SIKORA AG. On a rotational basis Mr. Prof. Thomas Sikora takes the chair on the Supervisory Board. Mr. Wolfgang van Hettinga and Martin Siemer remain on the Supervisory Board. The Managing Board of SIKORA AG would like to thank Mr. van Hettinga for his commitment in the last years, which has significantly contributed to the dynamic growth of the company.

The worldwide increased demand for products and support of the installed base, was the decisive factor for SIKORA INTERNATIONAL to move into an expanded office structure at their Peachtree City address. The adjacent office has been developed into new sales and administration offices, new technical laboratory as well as largely expanded warehousing facilities. The technical laboratory, supporting repairs, telephone support and all technical support requirements for the region has grown over four times the original office size. The total office size is now almost double the size of the original facility with a total of 4500 square feet in office and warehouse space. Ten staff members are working there and provide individual sales and services. "We see our expansion as another key milestone indicative of the steady and consistent growth of our company," says Jeffrey Swinchatt, president of SIKORA INTERNATIONAL. "This expansion facilitates our mission always to enthuse our customers ensuring excellent support and service on site."

SIKORA INTERNATIONAL with its headquarters in Peachtree City, GA, was founded in 1991 and is a subsidiary company of the Bremen, Germany based SIKORA AG. Internationally well known for its highly qualitative measuring and control equipment for the wire, cable and hose sector SIKORA is further pushing into uprising markets. Expansion of not only the Peachtree City operation, but offices in China and Brazil as well, has been demanded of the Company. In 2007 SIKORA AG finished the construction of a third building on their Bremen, Germany campus. At the same time their purchasing department moved into another building within the office complex. With a clear company structure and strong global presence SIKORA presents itself as reliable partner for measuring and control technology on the highest level of perfection.

With the new X-RAY 8000 NXT for XL diameters, SIKORA is now presenting a new model of this series, which combines the technological advantages of the X-RAY 8000 NXT with regard to the practical application in the field of EHV-cable (Extra High Voltage cable) production. The “measuring giant” is perfectly suitable for extremely big cable diameters of up to 7.09” (180 mm) for CCV-lines and 8.66” (220 mm) for VCV-lines. It provides highest measuring accuracy and repeatability while demonstrating the flexibility and safety of an X-RAY 8000 NXT.

Same as the X-RAY 8000 NXT, the XL-system requires only one scan to calculate all measuring values. Hence, all requirements for rapid centering of the extrusion tools as well as optimum control of the production line. Multi-sensor semi-conductor detectors are incorporated into the high-end variant of the X-RAY 8000 NXT. The multi-sensor-technology assures reliable readings and ensures reliable measuring values – even when the cable is vibrating. At each scanning process four measuring values are provided – for a remarkably precise measurement. A masterpiece of engineering is the integration of ceramic windows*, which separates the scanners from the pressure of the CV-line. This innovation replaces the previously used beryllium windows and prevents contamination in the measuring plane. The surface of the ceramic windows* does not react with any by-products and always remains clean without rinsing and mechanical protections.

The product planning of the X-RAY 8000 NXT was specifically adapted to the demands of the modern high-voltage cable production. Today, 500 kV-cables and higher are produced, with bigger wall thicknesses and a specific measuring plane. Additionally, the expansion of the hot material results in a bigger hot diameter. For the measurement of EPR-cables with extremely big diameters SIKORA offers an innovative 70-kV-scanner-model, to permanently guarantee highest quality at the production.

In practice the X-RAY 8000 NXT stands out for its high efficiency. With regard to eccentricity, the wall thickness is measured and controlled, for highest quality and productivity. Simultaneously, the material consumption is reduced and results in cost reduction.

* patent pending

With the X-RAY technology, the hose or tube is transilluminated by X-rays. Measuring values are continuously available within fractions of a second. With the X-RAY 2000 customers achieve a fast centering of the crosshead and a permanent measurement as well as control of the extrusion line under consideration of the minimum values.

The measuring values of the X-RAY 2000 are displayed graphically and numerically on a 15” TFT-color monitor on the processor system ECOCONTROL 2000. In case of an eccentricity, the wall thickness is displayed as an eccentric ring. In the graphical display, the position, where the wall thickness is thinnest is highlighted as a bright colored segment. As a standard, the X-RAY 2000 provides a statistical evaluation of the measuring values, which are graphically displayed in a length or time related diagram in combination with a graphic display for the statistical distribution of the single measuring values and statistical data.

The advantages of the system are obvious: Calibration procedures are only done during production before initial operation and not necessary afterwards. With the measuring values available immediately at the start-up of the line and with the continuous measurement, the X-RAY 2000 becomes a tool, which is of essential importance for tube and hose extrusion lines, where beside tight tolerances for the products the economical aspects at the production and the quality control are important.

The measurement of the wall thickness, eccentricity as well as the inner and outer diameter is increasingly important in global competition. For customers in the hose and tube industry two criteria are of main importance: continuous quality assurance and the reduction of material over consumption to achieve a lasting cost reduction. The X-RAY 2000 guarantees a continuous online quality control and thus provides the highest technological potential for savings with regard to the elimination of start-up scrap and material over consumption.

CENTERVIEW 8000
SIKORA is presenting the remarkable CENTERVIEW 8000 developed for the special demands for quality and productivity at the production line. CENTERVIEW 8000 includes a unique non contact measuring head that allows a continuous on-line measurement. Furthermore, an 8-point eccentricity measurement, 4-axis diameter and 8-point ovality measurement provide highest precision. The measuring system is perfectly suitable for the production of telephone wires, coaxial cables, LAN-cables as well as automotive and building wires. SIKORA offers two CENTERVIEW 8000 models that are specifically compatible with diverse product dimensions to serve individual customer demands. CENTERVIEW 8010 is applicable to products with a diameter from 0.1 to 10 mm while CENTERVIEW 8025 is particularly conceived for bigger product diameters from 0.5 to 25 mm. Unique is the auto positioning of the gauge head to the cable position. In order to receive precise single measuring values even in the sub micrometer area, the design of the measuring head does not include any rotating mirrors, optical lenses or guide rollers.

CENTERVIEW 8000 records single measuring values with highest precision and depicts them in the form of points in a unique cloud diagram (patent pending) display. Rapidly, the operator gets clear information about eccentricity values that can optimally and promptly be controlled by means of specific controlling procedures. “With our innovative and powerful technology we further want to raise the bar regarding quality, productivity and cost reduction in the segment of premium measuring devices”, says Jeff Swinchatt, president of SIKORA INTERNATIONAL CORPORATION. CENTERVIEW 8000 sets new standards through its technological fully developed measuring procedure.

Outstanding innovations of the device are high accuracy, easy handling as well as a continuous online quality control at the production process. X-RAY 2000 is suitable for the measurement of the wall thickness of the cable continuously at four points (at the top, at the bottom, left and right) and always guarantees flexible solutions for specific products. The system additionally provides diameter and ovality values and at the same time offers the capability to control the manufacturing process by wall thickness or diameter.

The display and control device of the X-RAY 2000 series is ECOCONTROL 2000, a powerful processor system, which permanently provides precise measuring values and ensures highest quality standards. A length- or time-related diagram for the measured dimensions and a display of the statistical distribution curve of the measurements is offered. With SPC-data of the minimum, maximum value, the mean, standard deviation, Cp, and Cpk values the operator has all the information necessary to correctly control the extruder output or the line speed.

Meet our team of SIKORA on booth 117/119 and get to know our exciting product range. We look forward to seeing you at the Wire Expo!

Best performance demonstrated also the SIKORA booth: On 192 sqm and two floors SIKORA presented a business strategy of future-orientation. Besides the first floor, where all measuring and control systems were exhibited, a second floor in modern lounge style created a pleasant atmosphere for customer conversations. “The second floor as well was enthusiastically received by customers. From this “outstanding” position you could easily watch the fair goings”, says Harry Prunk, chairman of SIKORA AG. “Our customers immediately felt comfortable at our booth, which contributed to the further development of business connections and to make new contacts”, explains Prunk further. Additionally, light refreshments were served. A cook supplied the customers during lunchtime with culinary delicacies.

The motto „the best“ was also suitable for SIKORA’s measuring and control devices. Especially new developments were in the spotlight, such as the X-RAY 2000 for the direct measurement of the diameter, wall thickness, eccentricity and ovality at the production line or the new LED 8000 XY, the first diameter gauge head with an LED light source, which also measures transparent products with highest reliability. The high achievers were the sophisticated diameter measuring devices of the LASER 2000 series as well as the new display and control system ECOCONTROL 600, that clearly presents the measuring values of the connected measuring devices on a 8.4“ TFT-color monitor and controls the production process.

With its innovative non contact measuring and compatible control systems SIKORA occupies a niche for products, for which specifically high requirements are made. Precondition is the permanent research and development for improved product solutions at the headquarters in Bremen, which ensures that SIKORA reacts quickly to changing market conditions. „The global demand for measuring devices in the cable and hose and tube sector is enormous. In general, there is a positive movement towards high-quality and reliable products“, explicates Prunk. Latest numbers of customer contacts on the SIKORA booth confirm this upswing. „The number of visitors has increased by 45 % compared to the Tube/ Wire 2006. SIKORA’s innovative measuring devices belong to the best worldwide and are the powerhouse driving for the measuring devices of the future”, concludes Harry Prunk.

CENTERVIEW 8000: Exemplary reliability, optimum quality and substantial cost reduction
At an exhibition area of 144 sqm SIKORA is presenting the remarkable CENTERVIEW 8000 developed for the special demands for quality and productivity at the production line. CENTERVIEW 8000 includes a unique non contact measuring head that allows a continuous on-line measurement. Furthermore, an 8-point eccentricity measurement, 4-axis diameter and 8-point ovality measurement provide highest precision. The measuring system is perfectly suitable for the production of telephone wires, coaxial cables, LAN-cables as well as automotive and building wires. SIKORA offers two CENTERVIEW 8000 models that are specifically compatible with diverse product dimensions to serve individual customer demands. CENTERVIEW 8010 is applicable to products with a diameter from 0.1 to 10 mm while CENTERVIEW 8025 is particularly conceived for bigger product diameters from 0.5 to 25 mm. Unique is the auto positioning of the gauge head to the cable position. In order to receive precise single measuring values even in the sub micrometer area, the design of the measuring head does not include any rotating mirrors, optical lenses or guide rollers. CENTERVIEW 8000 records single measuring values with highest precision and depicts them in the form of points in a unique cloud diagram (patent pending) display. Rapidly, the operator gets clear information about eccentricity values that can optimally and promptly be controlled by means of specific controlling procedures. “With our innovative and powerful technology we further want to raise the bar regarding quality, productivity and cost reduction in the segment of premium measuring devices”, says Harry Prunk, chairman of SIKORA AG. CENTERVIEW 8000 sets new standards through its technological fully developed measuring procedure.

Meet our team of SIKORA on booth 9 A41 and get to know our exciting product range. We look forward to seeing you at the Wire!

Located in the center of all commercial activities, the Suzhou office will contribute to the further continuation of existing customer relationships and allows for many opportunities to network and establish new sales leads. The decisive reason for the opening of the office is to increase customer support on site. Wanbin Chen, head of SIKORA ASIA, feels very confident about the business expansion. “We decided for the additional sales location to be more flexible and able to specifically address and attend customers on time. Our customers can expect a more convenient service which includes lower service costs due to shorter travelling ways. As we also engaged new employees we can more profoundly react on individual customer needs and most of all we can improve the information flow with them. Simultaneously, our objective in establishing a second office here is to raise awareness about our products and to convey SIKORA’s company image of future-orientation”, explains Chen.

SIKORA ASIA was founded in 1991 and is a subsidiary company of the Bremen/ Germany based SIKORA AG. Internationally well known for its highly qualitative measuring and control equipment for the wire, cable and hose sector SIKORA is further pushing into uprising markets. The headquarters of SIKORA ASIA is situated in Fuzhou, in the southeast of China. Ten employees are working there and provide individual sales and service. With the decision for the additional location SIKORA ASIA actively follows the strategy of world wide representation framed by the SIKORA parent company. The economic upswing of the Chinese Market motivates many customers to make concrete investments in the field of measuring devices for the cable and plastics branch. This trend follows firm intentions of large companies, especially machine manufacturers to invest in completely new production lines. The country’s know how and development potential has positioned China at 3rd position among the top 20 exporting nations worldwide in 2007. Over the next years China will further play a major role for the cable and tube sector.

SIKORA ASIA Suzhou Address:
Room 614, Sucheng Business Center,
No. 1607 Renmin Rd. Suzhou City,
Jiangsu Province,
P.R.China

Phone: +86-512-67773543
Fax: +86-512-67772647

Contact: SIKORA ASIA Fuzhou,
Suzhou, P.R. China
Email: sales@sikora-asia.net
Website: www.sikora.net

The latest LED-diodes combined with high resolution CCD-lines create the foundations for a top class future-oriented measuring device. With the help of a powerful software the shadow width of the measuring object is calculated and the outer diameter precisely defined. Especially unique is the measurement of those cables which have a transparent insulation layer. Within this application field the LED 8025 XY also guarantees optimum reliability. The integration of state-of-the-art SMD technology ensures the gauge head is very small and can easily installed into any production line. The LED 8025 XY is designed for product diameters from 0.25 to 25 mm.

The traditional strengths of measuring systems by SIKORA include maximum measuring precision, and long-life reliability. The gauge head is equipped with vertically arranged glass windows, which offer an efficient protection against dirt. Additionally, the LED 8025 XY is open at the bottom which prevents both dirt and water contaminating the measuring area. The lack of wearing parts creates a unique freedom from maintenance. The LED 8025 XY flexible design ensures an unrivalled process optimization and cost reduction.

Several interfaces

The LED 8025 XY is equipped with a RS 485 serial interface and RS 232 diagnostic interface for the direct connection of a line control system or SIKORA’s control devices REMOTE 2000 or ECOCONTROL 600, 1000 and 2000. Optionally, it also offers an Ethernet RJ45, Profibus interface or even an analog output.

"Our new website design, offers specific issues in greater detail. From corporate information to product news and topics such as environment and corporate social responsibility, visitors can quickly enter the fascinating world of SIKORA and gain an interactive experience on the potential of our company,” says Harry Prunk, chairman of SIKORA AG. The website provides continually updated information and news about upcoming events always to keep visitors informed on time. “The rotating globe corresponds to our corporate philosophy: We are manufacturing our high-quality products in Bremen and guarantee with the support of several offices and representatives worldwide individual sales and services on site. We are constantly advancing on developing new technologies to enthuse our customers and to be always one decisive step ahead in the world markets.”

With the new website visitors receive a stronger multimedia brand experience, and can quickly and easily inform about products and company news. Additional features such as product videos, a newsletter or the Return on Investment Calculator (ROI) round off the digital channel of information. The website technology allows faster Internet connections and also makes it possible to achieve higher screen resolutions. By using a clear site structure and a rotating globe in corporate SIKORA blue the pages communicate the typical SIKORA design. Visit the new SIKORA website on www.sikora.net  and get an impression on the great capacity of SIKORA!

Just in time for the 20th anniversary of the most known norm of all times, ISO 9001, SIKORA, worldwide manufacturer of measuring and control devices for the wire, cable and hose markets, celebrates 14 years of ISO certification. Since 1993 the technology company has been certified according to DIN EN ISO 9001 and practices quality management to perfection.  The company management is committed to the principles of the program and the primary responsibility for daily oversight is the quality control manager Dipl.-Ing. Ulrich Gwinner. For 14 years he has controlled and managed the quality system – with notable success. For Gwinner quality is the basis to satisfy customer demands for product and service performance. “With the improvement of our operational sequences we meet legal demands and simultaneously aim at a systematic increase of customer satisfaction. Moreover, with the ISO-certification our market position can be further strengthened and extended,“ says Gwinner.

Gwinner continuously analyzes the business processes in the different departments of the company in cooperation with the company management and employees. Through the use of statistical analysis and operational measurements the identification of potential sources of defects can be made.  Process improvements then may be implemented to meet the goal of increasing employee consciousness of methodical operating processes and self-dependent quality control.  All procedures, at the different company levels should smoothly mesh with improvements systematically initiated. With the ISO 9001 certification SIKORA confirms to its customers that the workflows are subject to clear rules and constantly monitored, a check and balance insuring a quality end product.

For the continuous improvement of quality, internal and external employee training is provided numerous times during the year.  Of great importance is the company’s cooperation activity with machine manufacturers and customers in the various markets to address worldwide performance requirements while optimizing the manufacturing process. “The formula of success of a sustained quality management contains clear and transparent processes that is to say a process oriented leadership, flat hierarchies and a good communication.“, says Gwinner. “Feedback and suggestions for improvement from the employees are decisive factors for a successful quality management system“, explains the quality control manager further.

Long lasting investments over the recent years in service, delivery and quality orientation have proven to be extremely profitable today. With more than 150 employees worldwide SIKORA generated a consolidated turnover of 27 million euros in 2007.

Prepare yourself for an exciting visit to this year’s Interplastica 2008 in Moscow! SIKORA AG, manufacturer and worldwide vendor of pioneering measuring, controlling and testing equipment for the plastics and rubber industry will attract attention with the presentation of cutting edge products such as the LASER 2000 and X-RAY 2000 series. On the exhibition area the Germany-based company presents its innovative range of products and invites interested visitors to see for themselves the latest measuring and control devices.

Continuous online quality control with the LASER 2000 series
For the precise measurement of the outer diameter of a product during the production the SIKORA XY and 3-axis gauge heads of the LASER 2000 series set new standards. The different gauge head models guarantee reliable measurements of hoses and tubes with a diameter from 0.05 to 300 mm. The sophisticated combination of a laser diode as light source with a CCD-line sensor provides high quality measurements. The outer diameter is automatically calculated from the shadow image. All LASER 2000 gauge heads provide 500 measurements per second and ensure with an exposure time of 1 µsec highest precision even if the product is vibrating or moving as typically seen during the production process. No moving parts and optical components are integrated into the systems which eliminate wearing and maintenance procedures. Due to the highly technological standard calibration is also not necessary.

X-RAY 2000: successful measuring technology for extrusion lines
X-RAY 2000 for the measurement of the diameter, wall thickness, eccentricity and ovality at the production line will be a major visitor attraction at the SIKORA booth. It presents itself as a remarkable generation of measuring systems for the reduction of production costs through minimization of start-up-scrap and thus reduction of material consumption. Outstanding innovations of the reliable X-ray measuring device are high accuracy, easy handling as well as a continuous online quality control of products with up to 3 layers. X-RAY 2000 is suitable for all hoses and tubes from 3 to 300 mm and always guarantees flexible solutions for specific products. The display and control device of the X-RAY 2000 series is ECOCONTROL 2000, a powerful processor system, which permanently provides precise measuring values and ensures highest quality standards. A length- or time-related diagram for the measured dimensions and a display of the statistical distribution curve of the measurements is offered. With SPC-data of the minimum, maximum value, the mean, standard deviation, Cp, and Cpk values the operator has all the information necessary to correctly control the extruder output or the line speed.

The concept of the Virtual Gauge Technology

Simulation Technology
Virtual Gauge Technology is the next chapter of measuring technology for the wire and cable sector. This technology developed by SIKORA innovatively controls the wall thickness of the product quickly and precisely at the requested nominal value even though a measurement of the wall thickness immediately after the extruder does not occur. The virtual measurement is still authentic.

Forward Thinking Design
Previously lines with a relatively low haul-off speed could not control the extruder from the end of the line due to the dead time resulting from the distance of the measuring device to the extruder. VGT eliminates this lag time and shows even during the start of the production the expected cold wall thickness despite the product not having arrived at the end of the cooling section. The measuring device is installed at the end of the cooling section for this method. Issues such as contamination, water influence or mechanical load, all of which occur with placement directly after the extruder are eliminated.

The extruder can already be controlled by the VGT during the starting phase to the calculated rpm that is necessary in order to achieve the entered cold nominal wall thickness. The specification of a cold wall thickness value is a decisive advantage over conventional methods where the extruder rpm is entered and as a result a wall thickness value is achieved. The control of the extruder is in consideration of the inserted haul-off speed. The virtual measuring gauge head calculates the extruder rpm to realize the specified wall thickness. The measuring device after the cooling section balances the actual wall thickness against the predicted one and controls the extruder to the requested wall thickness as necessary.

Intelligent Software Concept
The basis of the design is the identification of the extruder through the measurement of its volume output. The volume output is recorded in a user friendly way by the processor system ECOCONTROL 2000. ECOCONTROL 2000 displays the virtual as well as the real measuring value clearly on a 15“ TFT-monitor that can be used per touch-screen. If there are several extruder screws in use, their volume output will also be collected. New material types do not demand an addition of the volume output, but only a short calculation of the material-specific factor with the help of ECOCONTROL 2000. In the event of exceeding the control limit the system informs the operator and gives visual information that he has undertaken a material change that he must notify to the system.

Real advantages
In practice, the VGT is extremely reliable whilst predicting cold wall thickness and guaranteeing accurate control of the extruder. The measuring system at the end of the line measures the real values of the product which are then incorporated into the control. The VGT is compatible with the X-ray measuring devices X-RAY 2000 as well as the laser measuring systems of the LASER 2000 series. It is perfectly suited to application in the hose and tube sector. The virtual measuring head combines typical features of a real gauge head such as precision and reliability with the advantage of technological progress in production efficiency optimization and cost reduction.

The SIKORA booth at the K

The LASER 2000 series grows
The highly versatile LASER 2300 XY expands the LASER 2000 XY series and fulfils customer demands for measuring gauges for very big product diameters. As all SIKORA products the new gauge fascinates through its state-of-the-art CCD-line technology and impulse-driven laser-light sources, which allow extremely short exposure times of 0.3 µsec and ensure a measurement of highest precision at all line speeds. The gauge head is strikingly powerful and can easily be integrated into every location on the production line despite its size. The design of the LASER 2300 XY is exceedingly well thought out: The gauge head is open at the bottom and provides reliable measuring values in places with high levels of contamination. After years of operation the system will remain as precise as on the first day, without any calibration. The almost unlimited operation time of its laser light sources and the elimination of moving parts ensure freedom from maintenance.

Virtual Gauge Technology for a reliable and fast measuring value control
With the new Virtual Gauge Technology SIKORA presents a unique method to optimize the extrusion process, to minimize the material over consumption and to simplify the operation of an extrusion line. The excellent potential of the Virtual Gauge Technology is especially noticeable for specific line configurations or individual product compositions. Immediately after the extruder a diameter and wall thickness measurement can be done with the new concept. The superior technology controls the wall thickness of the product quickly and precisely at the nominal value even though a measurement of the wall thickness directly after the extruder does not take place. The basis of the design is the identification of the extruder through the measurement of its volume output. The volume output is recorded in a user-friendly way by the processor system ECOCONTROL 2000 in combination with a measuring device. ECOCONTROL 2000 displays the virtual as well as the real measuring value clearly on a 15” TFT touch screen monitor. The measuring device after the cooling section balances the actual wall thickness against the predicted one and controls the extruder to the specific wall thickness if necessary. Harry Prunk, chairman of the SIKORA AG: “This concept is perfect testimony to the aspirations and expertise of SIKORA in building the most exciting measuring systems for our customers in future.”

X-RAY 2000: successful measuring technology for extrusion lines
X-RAY 2000 for the measurement of the diameter, wall thickness, eccentricity and the ovality of tubes and hoses at the production line was a major visitor attraction at the SIKORA booth. It presents itself as a remarkable generation of measuring systems for the reduction of production costs through minimization of start-up-scrap and thus reduction of material consumption. Outstanding innovations of the reliable X-ray measuring device are highest accuracy, easiest handling as well as a continuous online quality control of products with up to 3 layers. X-RAY 2000 is suitable for all hoses and tubes from 3 to 300 mm and always guarantees flexible solutions for specific products. The display and control device of the X-RAY 2000 series is ECOCONTROL 2000, a powerful processor system, which permanently provides precise measuring values and ensures highest quality standards. A length- or time-related diagram for the measured dimensions and a display of the statistical distribution curve of the measurements is offered. With SPC-data of the minimum, maximum value, the mean, standard deviation, Cp, and Cpk values the operator has all the information necessary to correctly control the extruder output or the line speed.

Positive Show conclusion
The long-standing brand SIKORA, whose excellent reputation worldwide goes back to the legendary development of non-contact measuring systems for energy cables in the 1970s, is now benefiting from this lead in the hose and tube industry as well. For four years SIKORA has also been serving the hose and tube market and today records similar turnover increases like in the cable sector of about 20 to 40 %. With innovative measuring and control devices SIKORA occupies a niche for products, for which no satisfying solution exists until now. The requirement is continuous development and research for improved product solutions at the headquarters in Bremen, in order to react to changing market conditions. Latest numbers of customer contacts at the SIKORA booth confirm this uptrend. The number of visitors has increased by 50 % compared to K-2004. Moreover, the quality of the conversations has also improved. Similar developments were already noticeable at the „Tube Southeast Asia“ in mid-October this year. “The demand for measuring devices in the hose and tube sector is enormous. Not only the European, but also the Asian market offer high potentials for qualitative products in this field. SIKORA’s technology concept is the new benchmark for all production lines and, in turn, the powerhouse behind the sector of premium-class measuring devices of the future”, concludes Harry Prunk.

The SIKORA booth at the WIRE Southeast Asia

The atmosphere at the BITEC exhibition center was extremely busy and exciting. One reason is the current positive economic situation in Southeast Asia. The economic upswing motivates many customers to make concrete investments in this sector. This trend follows firm intentions of large companies to invest in completely new production lines. So the Wire Southeast Asia was timely with Thailand’s aspiration to be “The Hub of Asia” as Khun Chakramon Phasukavanich , Secretary of Thailand’s Ministry of Industry asserted at the opening of the fair. Another reason for the success of the inauguration of the trade fair was the excellent organisation and smooth performance of the fair on the part of the organisers that contributed to the active and pleasing atmosphere.

The high number of visitors on the SIKORA booth on the first two days was extraordinary. ”in peak hours the trade show visitors seemed to push their way onto our booth”, said Harry Prunk, chairman of SIKORA AG. In many interesting and professional customer conversations a panel of four SIKORA experts informed their customers about the wide range of innovative measuring and control devices. “In my opinion the show was effective. It provided a lot of connections and allowed for many opportunities to network and establishes sales leads”, explains Prunk further. The main attractions on the SIKORA booth were X-RAY 2000 as well as the LASER 2000 series and the new X-RAY 8000 NXT. Actually, a contract for the X-ray measuring system of the new generation was signed during the fair. Moreover, the new eccentricity and diameter measuring device CENTERVIEW 8000 sparked interest as well as the graphic display of single eccentricity values as a cloud diagram on the processor system ECOCONTROL 2000.

All the serious and qualified discussions of the SIKORA representatives with existing and new customers on site are a clear sign for the trust customers worldwide put in SIKORA technology and service. Thailand is a market that offers great potentials for the future. SIKORA’s objective in participating at Wire Southeast Asia to create more awareness of its products, brand name and image was successfully reached. As a consequence of this positive conclusion SIKORA will presumably return to the next Wire Southeast Asia in 2009.

The high-precision technology of LASER 2300 XY and its specific application for diameter measurements of exceptionally big product dimensions of up to 300 mm should enthuse customers of the hose and tube sector. The measuring technology of LASER 2300 XY allows extremely short exposure times of 5 µsec with state-of-the-art CCD-lines and impulse-driven laser diodes and thus guarantees a measurement of highest precision and repeatability at all line speeds. The gauge head is extremely powerful and due to its small dimension and modern SMD-technology (Surface Mounted Devices) almost applicable to every place in the production line without difficulty. The design of LASER 2300 XY is very convenient. The gauge head is open at the bottom side and provides reliable measuring values even at places of heavy dirt. Calibration procedures are exclusively done during manufacture and are not necessary afterwards. Moreover, LASER 2300 XY fascinates as a result of the almost unlimited life time of its laser diodes, the measuring principle without moving parts and its freedom from maintenance.

In all production lines LASER 2300 XY can be combined with the new processor system ECOCONTROL 1000 offering efficient production optimization. With ECOCONTROL 1000 SIKORA responds to individual customer demands and provides an attractive version complimentary to the ECOCONTROL 2000 with regard to price and performance. It offers connections for 2 measuring and 2 testing devices of the SIKORA INLINE 2000 series. The slim processor system clearly displays measuring values and statistical data on a 15" TFT-color monitor and is offered with a user-friendly touch screen. The display of the measuring values is numerically and graphically represented. Further features of graphical length or time-related trending statistical distribution of the single measuring values provide detailed information for real time and post production analysis.

SIKORA will include at the K popular and successful measuring and control devices such as X-RAY 2000, for a non-contact measurement of the diameter, wall thickness and eccentricity or LUMP 2000 T for the detection of non-conformities in the product surface as well as ECOCONTROL 2000 "in action". Simulations of the operation of the devices will allow visitors to get to know how to optimize their production line and where saving potentials are possible.

Meet our team of SIKORA on booth 10 G21 and get to know our exciting product range. For further questions we will be available daily from 10 am to 6.30 pm. We look forward to seeing you at the K!

CENTERVIEW 8000 includes a unique non contact measuring head that allows a continuous on-line measurement. Furthermore, an 8-point eccentricity measurement, 4-axis diameter and 8-point ovality measurement provide highest precision. The measuring system is perfectly suitable for the production of coaxial cables, LAN-cables as well as automotive and building wires. SIKORA supplies two CENTERVIEW 8000 models that are specifically compatible with diverse product dimensions to serve individual customer demands. CENTERVIEW 8010 is applicable for products with a diameter from 0.1 to 10 mm while CENTERVIEW 8025 was particularly conceived for bigger product diameters from 0.5 to 25 mm.

In order to receive precise single measuring values even in the sub micrometer area, the design of the measuring head does not include any rotating mirrors, optical lenses or guide rollers. The device records single measuring values with highest precision and depicts them in the form of points in a unique cloud diagram display. Rapidly, the operator gets clear information about eccentricity values that can optimally and promptly be controlled by means of specific controlling procedures. "With our innovative and powerful technology we further want to raise the bar regarding quality, productivity and cost reduction in the segment of premium measuring devices", says Harry Prunk, chairman of SIKORA AG. CENTERVIEW 8000 sets new standards through its technological fully developed measuring procedure.

CENTERVIEW 8000 satisfies customer demands for reliability through its long operation time, which is emphasized by the Mean Time Between Failures (MTBF) of 12.8 years. The technology of the CENTERVIEW 8000 is a future-oriented, long-life product maintaining "like new" performance for many years. Technological innovations provide a system that offers the operator simplicity, reliability, and accurate measuring values. As a result of the automatic positioning of the gauge head to the cable position, guide rollers or a manual system configuration is not required. The elimination of moving parts and components ensures reliability at every line speed and guarantees freedom from maintenance. Calibration procedures are exclusively done during manufacture and are not necessary afterwards. Accurate measuring values, highest quality, optimization of the production as well as simultaneous cost reduction are the matchless advantages of the new CENTERVIEW 8000. With this new model the success story of CENTERVIEW 2000 will continue. More than one hundred of these systems have been sold worldwide since their launch in 2000. The CENTERVIEW 8000 is exclusively produced in Bremen, Germany, home of many other worldwide technically recognized products, further assuring continued success. SIKORA once again presents a first class technology that sets new standards in the market.

Significant turnover increase
For many years SIKORA AG has been acting extremely profitable in the field of measuring- and control technology for the wire and cable industry. With the expansion of its product range for the hose and tube sector and always offering the highest degree of innovation and service SIKORA sets new standards. In 2006 SIKORA AG recorded a significant development. With an annual turnover of 17 million euro the technology company achieved a turnover increase of 15 % compared to the previous year. Increased customer demands for powerful measuring devices led to a need for employees and for larger production space. SIKORA AG, which was originally made up of a one-man-company, has more than 150 employees worldwide today. The first-class products, which are based on X-ray and laser technology, are exclusively made in Bremen, Germany. International representatives in the USA, China, Russia, Korea, India, Italy and the Ukraine as well as more than 30 regional offices guarantee sales and services on site. The increase of the contract volume and the workforce resulted in the decision for the extension of the global headquarters of SIKORA in Bremen.

High level of customer orientation
The positive business development can be traced back to the permanent development of the products. Apart from that, SIKORA reacted early enough and specifically to the requirements of global competition. Customers in the wire and cable industry primarily benefit from highest quality standards which represent SIKORA's highest goal. Therefore, the company fulfils all requirements in accordance with DIN EN ISO 9001:2000. Process orientation and standardized operational procedures guarantee the customer productivity optimization and cost reduction. "Customer satisfaction has top priority, says Harald Sikora, founder and president of SIKORA AG. To remain among the top ranked international manufacturers of measuring and control devices, we permanently have to deal with individual customer demands with regard to quality, costs and delivery reliability."

Future-oriented and highly qualified
As a result of these economic considerations SIKORA invested increasingly in research, in order to meet all requirements for powerful and innovative products. The success is already reflected in various new measuring devices such as X-RAY 8000 NXT, LASER 2003 XY, LASER 2300 XY or the processor-based system ECOCONTROL 1000. There is no end in sight to the current expansion. "If the trend of the continuously increasing demand will persist we will have to take further possible extensions into consideration, in order to be able to serve the international market at any time", explains Sikora.