FWB Brökelmann /E

Machine technology for the production of a vehicle part for the MERCEDES C-Class

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Made in Switzerland


  • No cracking in the bending area compared to other bending methods
  • Lower machine/tool costs compared to other bending processes
  • Simple correction for material batch-related deviations through modern software solutions


  • Process-compliant equipment of the machine and tool technology for 3 machines
  • Three-roll profile bending technology specially developed for this project combined with mandrel bending technology
  • Turnkey facility incl. SICK area scanner
  • Training of the employees regarding the operation of the profile bending machine


  • Realisation of a bending solution for the shaping of a vehicle part in the engine compartment of a premium vehicle
  • Challenges were posed by the cross-sectional change of the hollow chamber, which was only permitted to a small extent
  • Configuration of the profile bending machines for automated bending operation

FWB Brökelmann

F.W. Brökelmann Aluminiumwerk GmbH & Co. KG, now part of the Knauf Interfer Group, relies on three-roller profile bending machines supplied by PBT Germany GmbH, formerly INDUMASCH GmbH, now a subsidiary of PBT Profilbiegetechnik AG, to process aluminium hollow chamber profiles for the automotive industry. The profiles are components for the engine compartment of the Mercedes C-Class. In order for the final product to meet the required quality characteristics, all components must be bent absolutely identically. This demand for precision is met by the PBT25 three-roller profile bending machines, which are configured for automated bending operation. In addition, the standard versions of the machines have been equipped with a mandrel bending device. In this way, they meet further company specifications and ensure that the cross-sectional changes of the hollow chambers are only very slight. After the three-roll profile bending process, the profiles are punched in a press, cut and then deburred. The small change in cross-section is the prerequisite for successfully carrying out the downstream second bending process in the hydroforming process.

The use of a state-of-the-art PC control system also allows the employees to access a database that permits the storage of countless programmes. The flexible and intelligent software with the option of graphic display calculates the complete programme sequence, also taking into account material batch-related deviations in the bending process. Their correction is made completely effortless thanks to modern software solutions. The control system uses a Windows operating system and can therefore be easily integrated into the existing company network. In addition, a Siemens PLC in the background opens up the possibility for expansions and can thus be individually adapted to existing requirements at any time, such as automatic minimum quantity lubrication for gentle material handling of the profiles or the additional safeguarding of the system by SICK area scanners of the latest design. The robust industrial PC, including a 15-inch screen with infrared touch technology and the most important operating keys, is housed in a mobile control panel.

The claim of the F.W. Brökelmann company, namely to always offer the highest quality, is met thanks to the PBT bending machines including the user-oriented additional equipment.

Manufacturing advantage through PBT

FWB Brökelmann

Die F.W. Brökelmann Aluminiumwerk GmbH & Co. KG steht seit mehr als 100 Jahren für Know-how im Bereich der Aluminiumverarbeitung. Mit 22.500 Tonnen gepresstem Aluminium pro Jahr sowie Kompetenzen in den Bereichen Engineering, Produktentwicklung sowie Werkstoffoptimierung reichen die Leistungen des Unternehmens mit Sitz im nordrhein-westfälischen Ense-Höingen weit über die eines herkömmlichen Presswerkes hinaus. Am Hauptstandort sind rund 280 Mitarbeiter beschäftigt, die Spitzenprodukte für die Bereiche Industrie, Bau und Automotive fertigen