Ferrari, dry ice and Coca-Cola

valvescommunity®

Mario Principe, Sales Manager for CO2 and dry ice systems, reports: "In 1996 the Dry Ice Blasting Technology division, headed by Marco Pellegrino, obtained its first order in the automobile industry from Daimler AG. A few years later, this division also won a blasting competition with Ferrari in Maranello, and since then, this technology has been used there for cleaning casting tools for cylinder head production. In the meantime, other well-known car manufacturers now turn to the Swiss firm ASCO for all questions of dry ice blasting technology. "As an environmentally friendly, powerful and gentle cleaning method, dry ice blasting is unbeatable", says Principe, " and we have an especially good mastery of the technology".

This is only to be expected. "All about CO2" is the motto of the Swiss company, which is one of the world market lead-ers in the field of carbon dioxide. From CO2 production systems to CO2 tanks, dry-ice pelleting machinery or the dry ice blasting technology mentioned above - ASCO supplies everything. For many

Dear readers,

Even though the economy is slowly coming out of its turndown and the start of 2010 was very satisfactory for HEROSE, one thing still applies more than ever: If you don't continually ask questions and are not open to innova-tions, you will fail in the market. Be-cause of this, at present we are examin-ing our workflows together with experts - with the object of being able to cater for our customer's requirements even better. You can read more about the HEROSE "Lean Management" project on page 6. This time we have travelled to the Swiss side of Lake Constance for our customer report. This is the home of ASCO, one of the world's leading CO2 experts. ASCO? They are the company that makes your Coke fizz so nicely...

The Swiss firm ASCO is a world market leader in the field of CO2 for carbon dioxide, dry ice and dry ice blasters

Model of an ASCO CO2 system

years HEROSE products have been used for the construction of the cryogenic areas of the systems. Mario Principe:

Editorial

Issue 1 / 2010

Information for customers and partners

Dirk M. Zschalich, Wilfried W. ZschalichManaging partners

TitleFerrari, dry ice and Coca-Cola: Customer portrait: ASCO Interview"2010 began surprisingly well!"Lean Management The objective of the project: continuous improvementSouth America Great Success in Brazil with Mazbratech

2

Title Story

The ASCO headquarters in Romanshorn

"The valves from Bad Oldesloe are not only completely reliable, the service which the company provides is exem-plary. We are certainly very satisfied." The ASCO headquarters is located in Romanshorn on the Swiss side of Lake Constance. The Swiss company, which was founded in 1930, has about 90 em-ployees and is active in more than 100 countries and has branches in New Zea-land and France. Mario Principe: "Our experts travel all over the world to com-mission new plants." The CO2 production plants are mainly manufactured in New Zealand and then shipped for installation on site. Customers in this field include Coca-Cola, Pepsi and Schweppes - the major players in the aerated beverages market. However, ASCO is also active in the construction of water treatment plants throughout the world. Principe: "In this field our products are used for PH neutralisation."

The company management, including the planning department is located in Romanshorn. Mario Principe: "Almost every day visitors come from all over the world to discuss new systems with us." It takes an average of six months between the placement of the order and installa-tion. This is a surprisingly short time for systems of this size, which cost up to 1.5 million Euro. Production also takes place in Romanshorn. "For example, here we build CO2 bottle-filling systems, dry ice pelletising machines or dry ice blasting equipment and much more." ASCO does not produce common-or-garden prod-ucts. Paul Ruegg, Technology Manager in Romanshorn: "What we do, is a ma-jor challenge for any engineer. We have to design equipment which can not only withstand cryogenic temperatures down to minus 80 degrees - we also have to deal with an aggressive medium such as carbon dioxide. As well as this, the

equipment cannot be lubricated, be-cause it is used in the food industry. You need a great deal of experience to com-bine all of these factors."

CO2 – wasn't there a question about that? For both environmental and cost reasons, ASCO greatly relies on recy-cling. Ruegg: "Most of our CO2 is not produced by the combustion of primary energy sources, but rather it comes from residues from the chemical industry. A lot of pure CO2 is produced in the manu-facture of ammonia. This is compressed to between 16 and 20 bar, cooled to mi-nus 20 to 30 degrees Celsius - and then sold. "In Europe, all CO2 is a waste prod-uct of the chemical industry. In other countries we regrettably have to burn energy to produce CO2 because there is no alternative." On the other hand, in Eu-rope, dependency on others sometimes has undesirable consequences. Ruegg:

Dry ice blasting technology is an extremely efficient cleaning method, which is both environmentally friendly and gentle. On impact with the object to be cleaned, the blasting pellets produce a concentrated thermal shock. Because of this, the deposit or dirt to be removed contracts, and detaches from the sub-strate material. Only the detached soil-ing remains, because on impact, the dry ice immediately transforms into a gase-

ous state without leaving any moisture. This cleaning system has revolutionised many sectors of industry, such as tyre factories, foundries, food producers, printers, metalworking factories etc.

Dry ice blasting

Efficient, gentle and environmentally friendly

valvescommunity 1-2010 HEROSE GMBH valvescommunity 1-2010 HEROSE GMBH

Volker Maass (HEROSE) talking to Mario Principe

On this machine for the production of tennis balls you can see where the dry ice blaster

has already been used - and where not

3

"In summer, when chemical production is reduced for seasonal reasons, there are regularly CO2 shortages. At times, the beverage industry even has to stop production." Would it not be possible to solve the entire CO2 problem by recla-mation, even from smoking chimneys? "Unfortunately, things are not quite that simple", says Ruegg, "often the smoke is not pure enough and it is then difficult to reclaim the CO2. Complex technical purification and analysis is then neces-sary. "Another example of ASCO's opti-mal CO2 reclamation technology is the production of dry ice. Ruegg: "From 1 kilogramme of CO2 we can produce about 450 gramme of dry ice. However, the remaining gas does not escape into the atmosphere - it is returned to the CO2 tank and re-used for the produc-tion of dry ice.

On the subject of dry ice: ASCO is the undisputed market leader in this field. Mario Principe: "For example, our systems are installed at many airports throughout the world. These machines produce dry ice discs, which are used to cool food and drinks in aircraft trol-leys." Then there is dry ice blasting - also a field in which ASCO is the mar-ket leader. "This sector has developed greatly over the past 15 years, because dry ice blasting is superior to all other forms of cleaning," says Mario Principe. In this field, ASCO also supplies every-thing: Tanks, pelleting machines - and even the CO2, it is required. True to the company motto: All about CO2.

valvescommunity 1-2010 HEROSE GMBH

HEROSE valves for CO2 applications

Various HEROSE valves are used for a wide variety of CO2 applications. The same shut-off and safety valves as for air gasses are used for the transportation and storage of CO2. Type 15081 and 15086 ball valves are mainly used for ap-plications in which CO2 is in a gaseous state.

Because the medium immediately changes from a gaseous to a solid state (sublimation), securing vessels against excess pressure is a special problem. HEROSE solves this special task with the 06512 ball diverter valve, on which up to four safety valves can be mounted.

In general, type 06474, 06478, 06383 and 06388 safety valves are used for the following applications:n Cooling systemsn Blasting systemsn Dry ice productionnReclamation systemsnBeverage productionnWater treatment plant

Volker Maass (HEROSE) talking to Mario Principe ASCO employee Stefan Brunschweiler building a pelleting machine Paul Ruegg and Volker Maass with the dry ice machine

HEROSE ball valves 15081/15086 and safety valves 06474, 06478, 06388

4

The new year has started and the economy is gradually getting into its stride - Good reason for an interview with HEROSE Manager Dirk Zschalich

"The year began surprisingly well!"

vc: A last word on the subject of the past year 2009. Was it really that bad?Dirk Zschalich: No question. We had a reduction in sales of one third. That is very unsatisfactory, even though this was somewhat better than the German mechanical engineering sector as a whole. This had 40 percent less orders.

What about the outlook? How do you see this in the foreseeable future?There is no question that the market is recovering. However, i would hesitate to say that we can talk about real growth. You can only do this when we have achieved the sales figures for 2008. In my opinion, this will not be before 2012, 2013. This year we are forecasting a plus of 5 to 10 percent compared with 2009.

How did the year start?Surprisingly well. This applies to Janu-ary, as well as the first half of February (Editor's comment: further figures were not available at the editorial deadline for this issue).

Which markets are especially active at present?

China, India and eastern Europe. The German market is still very hesitant.

Which regions will you be paying special attention to in 2010?This will certainly be South America. Up to 2006, development in these coun-tries was rather lower than average. However, we are now seeing a positive development. This applies to Brazil, but even more so for Spanish-speaking countries, such as Argentina and Chile. As well as this, we are also setting our sights on Russia and the Ukraine. The USA will continue to remain a difficult market as long as the Dollar is weak.

What new products do you have in the pipeline?We are working at full pressure in all fields. This is the reason that we have re-structured our development department. Matthias Reinhardt has recently assumed the support of customised designs, while the fields of innovations and new devel-opments are now in the hands of Olaf Schulenberg. As product highlights, we wish to promote stainless steel safety valves for silo vehicles and cryogenic technology, and to increase their market penetration.

AIIGMA ROCKS in

Thailand

From 03rd to 04th February 2010, HEROSE participated in the 32nd AI-IGMA Seminar for industrial gasses in Bangkok, Thailand. In the course of the seminar, HEROSE presented its valves for technical gases and LNG applica-tions. For the first time a seminar of the "All India Industrial Gases Manufactur-ing Association" was held outside of India. With this, the AIIGMA wanted to provide its members with an opportu-nity to gain a better impression of the requirements and demands of the sec-tor in the region. The motto of the sem-inal was therefore "AIIGMA Rocks".

HEROSE was represented at the seminar by Wilfried Zschalich and Keith Stewart. During the seminar, Keith Stewart held a highly regarded lecture on the topic of "Global approvals - re-quirements and opportunities". Here he emphasised both the importance of global approvals in the technical gases industry as well as the benefits of ap-proved valves for tank manufacturers and plant operators. With the example of safety valves he gave a detailed de-scription of the relationships between - use of safety valves, safety valve func-tion, global approvals, approval costs and benefits for the industry.

Both during the seminar and in the course of a 2-week journey through India, Keith Stewart received confirma-tion that the growth of the market for industrial gases in India continues to exceed expectations. This is also due to the continued growth of the LNG market, which is gradually becoming established in addition to the existing LPG market and therefore continues to offer good opportunities for growth.

valvescommunity 1-2010 HEROSE GMBH valvescommunity 1-2010 HEROSE GMBH

HEROSE Manager Dirk Zschalich at his desk

HEROSE internHEROSE international

Keith Stewart (HEROSE Ltd.) with AIIGMA- President Mr. Karem Bhatia

5

In the past, the question often arose, as to whether the safe functioning of HEROSE safety valves for cryogenic applications is also ensured if no gas is removed from the tank. Of course, "no removal of gas" is a situation which none of our customers likes. However this of-ten occurs, for example in southern Eu-ropean countries at the end of the sum-mer holiday season. What is so special about this situation?

The liquid gas containers are filled to a level of 95 to 98 % with a filling pres-sure of about 2.5 bar. For nitrogen, the temperature of the liquid is then about minus 196°. If no gas is removed in this situation, the pressure in the storage tank increases to its maximum permis-sible operating pressure. For example, at 37 bar, this means an increase of the saturation temperature to minus 147° C, and the specific volume increases by more than two thirds. This great in-crease in volume would theoretically cause the tank to overflow, and without a safety valve it would burst. In Decem-

ber 2009, together with its customers Basi Schöberl and Linde, HEROSE sim-ulated exactly this application situation in the course of a 15-day test. For this, a 2,000 litre tank and a special vacuum pump were provided by the firm Basi Schöberl from Rastatt. To carry out the test, Linde provided a total of 8,000 litres of liquefied nitrogen. In order to increase the heat input into the tank even further, and therefore the probability of the oc-currence of the liquid phase upstream of the safety valve, the insulating vacuum of the tank was removed. In order that the safe function was also approved by an independent authority, the test was carried out under the supervision of TÜV NORD.

The question was then: "Can HEROSE safety valves safely release the pressure within the maximum pressure increase of 10 %, regardless of the occurrence of the liquid or gas phase upstream of the safety valve?"

The answer after the 15-day test is a definite "Yes"! At no time was there a

No gas removal ... what now?A 15-day test at HEROSE gave a completely satisfactory answer

critical operating condition, which could have destroyed the safety valve. Olaf Schulenberg, who has recently taken on responsibility for innovations in the HEROSE development department (see the interview on the opposite page), supervised the test: "The test records show that a safe function was ensured at all times. Both the subsequent leak test and the examination of the individ-ual components of the test valve were all positive: everything was within the manufacturer's tolerances."

In total, the safety valve opened and closed almost 1,000 times during the 15 days. With this, the test exceeded the requirements of DIN EN 13648-1 "Safety valves for cryogenic operation". The re-quirements for Category A valves: 1,000 switching cycles at ambient tempera-ture.

The test results also satisfied the en-gineers from Basi Schöberl and Linde, whose assistance made the perform-ance of this test possible.

valvescommunity 1-2010 HEROSE GMBH

Linde staff filling the test vessel from Basi Schöberl

The test safety valve on the right at the start of the test (top) and in an iced up condition after 4 hours (bottom)

Iced up safety valve outlet after 4 hours, with temperature sensor

6

Internal

valvescommunity 1-2010 HEROSE GMBH

The target: continuous improvementFirst experiences with the HEROSE Lean Management project are extremely positive

valvescommunity 1-2010 HEROSE GMBH

10 rules for lean managementIn the specialist literature, there are many overviews listing recurring points with various weightings, which are intended to lead to lean management. For example:

1. Orientation of all activities to the customer (customer orientation) 2. Concentration on company strengths 3. Optimisation of business processes 4. Continuous quality improvement 5. Internal customer orientation as the guiding principle 6. Independent responsibility, empowerment and team work 7. Decentralised, customer-orientated structures 8. management is a service to employees 9. Open information and feedback processes10. Changes to appointments and culture in the company

At first the staff were sceptical. "Lean Management" always sounds a little like job reductions. However, distrust soon tuned to enthusiasm: Ultimately, lean management means nothing less than continuous improvement - to the benefit of all. Customers, the compa-ny - and of course employees. Better products and better service usually mean better sales. And these are the best guarantee for job security. Stefan Gil, responsible for the HEROSE Lean

Management project: "In the CNC Pro-duction department, where we started the project, in the end employees even asked when it was the turn for their ma-chine.

Why is HEROSE questioning its own activities with lean management - an instrument which shook up the auto-mobile industry (Toyota) in the 90s? Manager Dirk Zschalich: "Because it is ideally suited to achieving our ob-jective, namely to reduce throughput

times, reduce stocks and shorten deliv-ery times." HEROSE took on the busi-ness consultants Vollmer & Scheffczyk as specialists for lean management. In autumn 2009 the programme started, which after Pre-production department will also make other HEROSE depart-ments fit for the future: the Assembly department, the Development depart-ment as well as the Administration. The ultimate goal is to optimally coordinate all activities which are necessary for value creation and to avoid unneces-sary activities.

At the start of implementation we held so-called 5S workshops, whereby the 5 S stand for "Sorting, Structuring and positioning, Systematic cleanliness, Standards and Self-discipline". The first results were seen immediately. Stefan Gil: "For example, previously there was quite a lot of confusion with our many different tools. If someone needed an Allen key, he was usually given an entire set". The solution: To-gether with the Production depart-ment, the necessary equipment was determined - an only this equipment is now available in the drawer. Result: 80 % of the tools could be disposed of. Even with the first two CNC machines, two complete cabinets were no longer needed. A further example: In future, each machine will have a decentralised data terminal, in order to save employ-ees the way to the central terminal - and therefore to save time. Even when all the workshops have been held for the employees on the CNC machines, from the middle of February a further lean management instrument has been available to all members of staff: a no-tice board, on which staff can put their suggestions for improvement on view to all. Even in several years time, this notice board will provide an intentional daily reminder of the principle of lean management. In the long-term the tar-get is continuous improvement and not just a nine day wonder.

Kaizen Management: the notice board with improvement suggestions

7valvescommunity 1-2010 HEROSE GMBH

One of us: Timo Warnke - interest-ed in technology

The fact that the photo of Timo Warncke was taken in the Production department and not at a desk was in-tentional. Although the 22-year-old is employed in the German Sales depart-ment, he has always been interested in the technical side: "In the final analysis, you have to know what you are selling." As his colleague Dietmar Mäding will be retiring in summer, the Ratzeburger will have to shoulder more responsibility in the future. Timo Warncke is a genuine home-grown HEROSE employee. "At the beginning of 2003, I started my training as an industrial business management assistant", says the athletic young man, who plays as a defender in the Ratze-burg SV in the regional football league and also goes to the gym twice a week. His field of responsibility, which he will share with colleague Julia Lindau in the future, is highly varied: "It ranges from order processing and the production of proposals to dealing with complaints and providing advice about products." One thing makes life difficult for him with his colleagues: Timo is an ardent fan of the German League club Bayern München.

France

Since 1997, Paul Robert has sold HEROSE products in France - one of the company's most important foreign markets. Near to Paris, together with his wife he runs the company Valvotec S.a.r.l., which also sells control valves for the energy and chemical industries.

Valvotec S.a.r.l.11 avenue de l‘Europe78130 LES MUREAUX, FranceTel.: +33 1 34 746 166Fax: +33 1 34 759 006E-mail: valvotec@wanadoo.fr

ItalienFrom Milan he deals with the whole of Italy: Andrea de Bernardi, who has been with HEROSE since 2006. One of his main customers is VRV, a company which manufactures tanks and trailers in Italy. "I like selling for HEROSE, because the products and services are good."

M.T. & P. srlViale A. De Gasperi, 8520017 Rho (MI), ItalyTel.: +39 0 293 90 62 45Fax: +39 0 293 90 43 32E-mail: a.debernardi@mtep.it

Paul Robert

Andrea de Bernardi

How to contact usHEROSE GMBHARMATUREN UND METALLE

Elly-Heuss-Knapp-Straße 1223843 Bad Oldesloe,GermanyPhone: +49 0 45 31 / 509-0Fax: +49 0 45 31 / 509 120E-mail: info@herose.de Internet: www.herose.com

Order the magazine: www.valves-community.com

The 5 winners of the last price game (MP4-player) are:Marcelo G. Insaurralde, Air Liquide, ArgentinaLuca Roncalli, VRV, ItalyHannu Pesola, Air Liquide, FinlandCarlos Matias, Cryolor, FranceJos Glorie, Cryonorm Projects, Netherlands

News

The next issue will be published in June 2010

nHEROSE now has approval for the Type 06217 safety valve for all Cana-dian territoriesn On 01.01.2010 Mr. Dankert-Paulsen took up his post as Sales Engineer and will initially provide support for custom-ers in South East Europe

n In December 2009 HEROSE was successfully recertified according to GOST R.n Correction:In issue 03/09, the article "One of us" should have stated: The resting period for a safety valve is 48 hours before the final setting

Published by:HEROSE GMBH, Bad Oldesloe

Responsible for content: Volker Maass, HEROSE GMBH

Concept, production: webhouse gmbh, Hamburg

Illustrations: www.designfreu.de, ASCO Switzerland, HEROSE GMBH

All rights reserved, subject to errata and printing errors

Imprint

8

Fairs calendar

Congratulations ...

on 10 years of service

Win a 1:43 model Ferrari 250 GTO

Send your solution to us by fax or by mail:win@valves-community.com, Fax: +49 (0) 4531 509 120 www.valves-community.com Deadline for answers is 5 May 2010. No right of appeal.

LPG, CNG, LNG + Industrial Gases Istanbul (TR)01.04 to 04.04.2010

CryogenicsBratislava (SK)26.04 to 29.04.2010

ITM Posen, Poland08.06. to 11.06.2010

MIOGE Moscow, Russia22.06 to 25.06.2010

First cryo-trailer for AL Brazil

valvescommunity 1-2010 HEROSE GMBH

Anja Schmidt on 01.03.2010Dieter Stahl on 14.03.2010Ingolf Günschmann on 10.04.2010, Rüdiger Hansen on 05.06.2010

Great success for the HEROSE agency Qualitec in Brazil: Marco Aurelio Casmal-la, who has worked for the Bad Oldesloe valve manufacturer from São Paulo has now equipped the first two cryo-trailers for AL Brazil. The vehicles were built by the Brazilian vehicle manufacturer Maz-bratech in São Paulo. The vehicles were accepted by Joâo Lacerda, Technical Manager of AL Brazil, and Milson Car-valho. During a trip to South America in November 2009, Volker Maass was able to get an impression of the capa-bility of Mazbratech: "This is an impor-tant breakthrough for us, as it is the first time that we have been able to success-fully compete with the Brazilian market leader. The Brazilian market is important for us because it is four times larger than the German market. For some time now, we have been negotiating with White Martins, the Brazilian Praxair subsidiary, Linde, Air Liquide and Air Products."

Volker Maass used the journey to South America for a meeting with Jorge Nuss-baumer from DEBENLUX. The Argen-tinean represents HEROSE interests in Argentina, Chile and Uruguay. For the first time, Maaß and Nussbaumer visited

potential customers in Montevideo, the capital of Uruguay.

The increasing importance of the South American market for HEROSE is also shown by the fact that in Septem-ber the company took part in the "Oil & Gas" fair in Rio Janeiro for the first time. Volker Maass: "In a similar way to the ACHEMA in Germany, this fair is an im-portant meeting place for manufacturers of valves and fittings."

Joachim Ehmke at the ITF

Zscharly conquers Bulgaria

HEROSE Sales Manager Joachim Eh-mke delighted these three Bulgarian girls. At the ITF Fair in Plovdiv, 150 km south of Sofia, he gave each of them a Zscharly polar bear. Ehmke regularly vis-its Bulgaria, where the market is still in the course of development.

Guiseppe De Santi (Mazbratech, Engineering Manager), Joâo Lacerda (Air Liquide, Engi-neering Manager), Milson Carvalho (Air Liqui-de, Engineering Mangement), Marco Aurelio Casmalla (Qualitec, HEROSE-representation)

How much dry ice can be prepared from 1 kg CO2

A about 450 g B about 750 gC about 600 g