Author: sertec_admin

This expansion highlights Sertec’s commitment to advancing EV technology and supporting the growing demand for sustainable transportation solutions.This new facility is designed to meet the stringent requirements of modern EV manufacturing, including high-performance insulation, high precision, and cleanliness. These factors are crucial for ensuring the safety, thermal efficiency, accuracy and longevity of EV batteries, which are central to the electric mobility revolution.

As the EV market continues to expand, the importance of effective insulation in battery systems has become increasingly evident. High-performance insulation materials are essential for electrical insulation, thermal management, energy loss reduction whilst contributing to the overall enhancement of vehicle efficiency. This trend is driving innovation in materials and manufacturing processes, with companies like Sertec leading the way in developing advanced sustainable engineering solutions.

The precision required in EV battery manufacturing cannot be overstated. Due to the compact design, close tolerances are required to ensure the design objectives are met. Sertec’s investment in these state-of-the-art production technologies at Wincaster House reflects the industry’s move towards higher precision EV components.

Sertec’s approach to EV component manufacturing is characterised by the integration of multiple advanced technologies. The new battery cell cover facility at Wincaster House combines precision stamping and surface preparation technologies with high quality insulation coating application at very high production rates. This holistic approach not only enhances the product demands but also positions Sertec as a leader in the rapidly evolving EV market.

Richard Sadler, Engineering Director commented, “Our investment in the new battery cell cover facility at Wincaster House is a testament to our commitment to innovation and excellence in EV technology. We are proud to be at the forefront of this exciting industry and look forward to continuing to support the transition to sustainable transportation.”

With this latest expansion, Sertec is well-positioned to meet the growing demands of the EV market and contribute to the development of cleaner, more efficient vehicles for the future.

The investment includes the introduction of a new 800T machine press at its Coleshill site, aimed at enhancing production capabilities and generating employment opportunities.

The unveiling of the new 800T Nidec Arisa Press took place during a special ceremony at Sertec’s Gorsey Lane production facility, officiated by Professor Carl Chinn, MBE. In order to commemorate the occasion, the first pressed part from the machine was presented to the esteemed Birmingham social historian and writer.

The fully operational 800T Nidec Arisa Press will play a crucial role in expanding Sertec’s parts production capacities across various sectors, particularly the automotive industry. Its implementation will facilitate the creation of 15 new positions following the complete integration of the 800T Nidec Arisa Press into the manufacturing facility.

Distinguished by its advanced functionalities, the 800T Arisa Press surpasses conventional presses by offering the ability to manufacture pressed parts through progression, transfer, or a combination of both methods. This versatility results in a more efficient and streamlined manufacturing process, enhancing the precision and speed of metal stamping operations.

The installation of the 800T Nidec Arisa Press commenced in the summer of 2023, involving the delivery of the 800T press and its components by 14 vehicles to the Sertec site. Subsequently, a team of 160 contractors dedicated over 16,000 hours to prepare and install the machine press, culminating in its full operational readiness by December 2024.

Grant Adams, Sertec Group CEO, said: “The installation of the 800T Nidec Arisa Press marks the completion of an 18-month project. The new press is a game changer, and we now have the capability to significantly boost our parts production process across all sectors.

“With our supplier Nidec Arisa, we have put a huge amount of engineering work into being able to incorporate many automated functions and pre-sets that run concurrently whilst changing coils or tools. This has resulted in changeover times that are now exceeding expectations and offering more flexibility for manufacturing parts from this press.

“The 800T Nidec Arisa Press installation forms part of a wider investment into our manufacturing process, which began earlier in the year. This is now producing the returns we had planned for with more jobs created, increased production capabilities and better efficiency in our business operations.

“Our focus is to now build upon this success, driving stability and sustainable growth to create a solid future for the business and all its stakeholders”.

Professor Carl Chinn said: “I can’t believe the size of the new press, it looks amazing. The basics of what it does, taking something and adding value to it, is at the heart of all that is good about the manufacturing industry.

“The West Midlands is an important place for manufacturing, and Sertec Group’s achievement with this project and everything else they are doing is helping to carry forward that proud tradition in the region.

“Thanks again to Sertec Group for what they doing for manufacturing and our country by actually making things.”

In recent years, Sertec Group has strategically focused on diversifying its product offerings and expanding into new customer markets. This strategic shift has allowed the company to develop expertise in Busbar technology and EV Battery Case Assemblies, while also expanding its customer base beyond the automotive sector.

In order to support this growth, Sertec Group has made significant investments in modernising its manufacturing processes and equipment. This includes the incorporation of advanced joining technologies like laser welding, high-speed automation, and robotic assembly cells with complex techniques such as flattening.

Furthermore, Sertec Group is heavily investing in research and development, site facilities, and technology. The company’s engineering department works closely with customers to design innovative and sustainable engineering solutions tailored to their specific industries, including automotive.

This year, Sertec has received recognition from prestigious organisations such as the Confederation of British Metalforming, naming them the 2024 Company of the Year. Additionally, they have been honoured with The Manufacturer MX awards as the 2024 Smart Factory Winner and 2024 Operational Excellence Finalist.

These accolades highlight Sertec’s commitment to industry leadership, excellence, innovation, and the integration of digital technologies into their manufacturing processes to drive efficiencies and informed decision-making.

By achieving these strategic goals, Sertec Group has positioned itself as a leading provider of sustainable engineering solutions, continuously striving for improvement and excellence.

With over 1200 employees across six global locations, including four UK manufacturing sites, a manufacturing site in Aszar, Hungary, and a tooling technical center in Dongguan, China, Sertec Group is dedicated to realising its vision to be the leading provider of sustainable engineering solutions.

The new assembly line will be fully operational in September 2021 and when in place will have the capability to produce in excess of 40 million electric vehicle battery Busbar assemblies per year. As the first mass production Busbar assembly line, it marks a vital step forward in electric vehicle technology for both the Midlands region and the UK.

Alongside the Busbar assemble line and at the heart of Sertec’s R&D investment is the fully equipped pre-production facility and testing lab. The Lab, built at a cost of £500,000 alone, has been invaluable in developing the Group’s abilities to design and test Busbars in modular battery production. The £1m pre-production facility has enabled Sertec to build protoypes and complete low volume orders for its customers. The production cell is currently being used to prove design concepts for assemblies requiring welding of dissimilar Busbar materials.

As well as developing new technologies essential for electric vehicle production, Sertec Group has also invested in similar technological innovation to support its customers in the consumer goods (FMCG) and distribution sectors.

Sertec’s investment extends to the recruitment of various highly skilled, specialist roles to support the technological innovation required within the EV sector.

Grant Adams, Group CEO at Sertec, said: “The investment we have made in new technology facilities are vital to the automotive industry’s ever evolving requirements for lightweight material production, which is set to become critical in future vehicle structures.

“As a UK first, the Busbar assembly line is integral to taking electric vehicle production forward both in the region and across the UK.

“It will help establish Sertec as one of the sector leading companies for this type of battery technology and put us at the heart of a regional manufacturing hub renowned for meeting the new technologic challenges of the future.”

With expansion into the electric vehicle sector key to Sertec’s future business vision, the Group is also preparing to build a larger footprint in mainland Europe, including bringing new leadership into the organisation. As a result, various senior staff have been recruited including a new European Sales Director, Chief Finance Officer, Vice President of Quality and Environmental Affairs, Vice president of Human Resource and a new Managing Director to run Sertec’s Hungarian facility.

Sertec are also looking to set up a technical centre in Germany, similar to the one they have in China.

The plan going forward is to repurpose the German plant as an electric vehicle component site using the know-how that’s been developed in the UK.