PECOL Automotive SA is a specialist in the automotive industry, producing cold formed fixing components. Opening in 2001 under the wing of the PECOL Group, the company has an impressive production capacity, manufacturing 130 million parts per month. Technical Manager Daniel Santos spoke in-depth about PECOL Automotive’s impressive production capacity and discussed the company’s most recent investments, in conversation with Imogen Ward.
The presence of an exceptional inhouse manufacturing process has solidified PECOL Automotive’s market lead in the production of automotive fixings. This extensive range of machinery has ensured the company can supply the highest-quality products to its clients in record time.
“We make everything in-house, except steel wire,” Technical Manager Daniel Santos said. “Because we can produce so much in-house, we are very flexible and adaptable. We don’t have to rely on anyone else, resulting in much shorter lead times for our clients.”
PECOL Automotive has been ahead of the manufacturing game since it was first established in 2001. With a plethora of support and knowledgeable experience provided by its parent (PECOL Group), the company has a strategic position within the automotive industry.
Alongside its headquarters, located in Águeda, Portugal, the company is supported by four PECOL Group industrial units located nearby. These units manufacture parts using cold forming, produce tools and special hard-metal parts, have heat treatment facilities and distribute PECOL products. The company also has supporting warehouses in Spain, Italy, Poland and Morocco. In Spain, the PECOL Group company INKATOR manufactures parts through cold forming. These facilities enable PECOL Automotive to manufacture 130 million parts every month – securing the company’s reputation as a steadfast competitor in the automotive industry.
PECOL AUTOMOTIVE I PROFILE
Integrated investments
After purchasing its first annealing furnace in 2017, PECOL Automotive opted to further invest in growth by acquiring a second furnace. This decision resulted in a successful expansion of the company’s production capacity and will lay the foundations for in-house steel wire p roduction. With this development, 100% of the production process will occur inhouse at PECOL Automotive.
“We have automotive tooling production and raw material annealing,” Mr Santos said. “For setting and conforming products, we have raw material pickling and phosphating. PECOL Automotive invested in a portfolio of machinery so our customers could have products delivered to them quickly and without delay.”
In more recent times, this integration has greatly aided the company. With global supply issues becoming increasingly problematic for many, using its in-house processes, PECOL Automotive has successfully minimised the impact of supply delays.
An investment of €1.5 million was also dedicated to the acquisition of a new in-line stamping machine. This purchase was in response to an increasing customer demand for larger parts. With this new machine, PECOL Automotive can now stamp parts that have a diameter of 33mm and are 180mm in length. This 450-ton machine enables the company to cold form, shear, die and bridge parts – making the whole production process more efficient.
Fixing the planet
To improve its sustainability, PECOL Automotive implemented a forwardthinking environmental management strategy. The company installed on its facilities 3,500 photovoltaic panels, covering an area of 10,000 square metres. To clean these panels, the company collects and stores rainwater (significantly reducing its water usage). This rainwater is also used to supply the factory’s tank for its firefighting system – highlighting the company’s dedication to a safer, more environmentally conscious future.
PECOL Automotive also sends all the wastewater from its productions to a dedicated facility where it is subjected to physical-chemical treatments. This process greatly reduces the environmental impact of wastewater disposal.
The company is really dedicated to finding unusual and ingenious ways to recycle: one way that PECOL Automotive achieves this eco-friendly goal is through the creation of a continuous oil lifecycle. All the oil used in PECOL Automotive’s stamping machines is processed through a filtration system.
This oil can then be reused in the stamping machines.
“By implementing these processes,” Mr Santos said, “not only do we actively save around €10,000 a month, but we are also helping save the planet too. This is so important to us.”
Forming strong connections
The company maintains robust relationships with its suppliers, including DIMAC who produce almost all of PECOL Automotive’s machines. “We have successfully maintained this relationship with DIMAC for over 20 years,” Mr Santos said, “relying on them not just for the manufacturing of our machines, but also for the upgrading and maintenance required to keep them in optimal condition.
“We always make sure to give feedback on the work of our suppliers. This client/ customer interaction is extremely important; without that you are not helping the suppliers to upgrade and improve their products.”
Thanks to the flexibility of its in-house manufacturing, PECOL Automotive has extensive product advancement opportunities. To maintain its reputation as a market leader the company also invests heavily in research and development. By monitoring the evolution of technology within the industry, PECOL Automotive can develop
300 new products each year (advancing and evolving alongside the market).
The company’s Engineering Department carries out equally complex and innovative projects, and continuously researches the best solutions for PECOL Automotive’s customers. This dedication ensures the most practical and quality-driven product is available, whilst still meeting client expectations and specifications. In doing so, the company maintains 100% control of the process, from design to production, giving its customers complete peace of mind.
PECOL Automotive also relies heavily on its workforce of over 270 professionals; with trust at the helm, the company prides itself in being internally autonomous when it comes to the development and construction of tools.
This creative freedom gives the company a strong competitive edge. Continuous training and experience also ensure PECOL Automotive’s engineers are some of the most competent tool developers in the industry.
“Our vision for the future will come to fruition with people who have knowledge of new technology,” Mr Santos concluded, “Our continued acknowledgement and investment of advanced technology, as well as our dedicated in-house manufacturing process, secures the future of the company.
“PECOL’s future relies on the people that work here: we will all continue to cooperate, solidifying the very best future for the company.” n
www.pecolautomotive.com
