For some time now, fittings manufacturer Mankenberg has been committed to using as little paper as possible throughout the company. The company is also pursuing a number of other sustainability goals, such as the economical use of materials in production. In an exclusive interview, Managing Director Dr. Stefan Nehlsen explains how the ecological balance is to be improved even further in the future.
Mr. Nehlsen, could you give us an overview of Mankenberg's sustainability strategy?
Stefan Nehlsen: Of course. The core of our sustainability strategy lies in the material savings of our products. We use a process that has been in place for 45 years, in which deep-drawn stainless steel is used. This modular system enables us to manufacture our fittings and valves with high efficiency and minimal material consumption. In addition, the stainless steel scrap produced is completely recycled.
What happens if a customer has special requirements? Does the material waste then increase?
In some cases, we use the solid material for special requirements, which actually leads to a higher metal surplus. However, this material is also fully recyclable. Mankenberg's sustainability strategy applies to our entire range. Interestingly, we recently received a request for a replacement valve that we first supplied in 1969. This illustrates the longevity and sustainability of our products.
In which industries are your products mainly used?
We serve around a dozen sectors, with the pharmaceutical industry being our largest field of application. This includes plant and mechanical engineering for the pharmaceutical industry. Other important areas are the chemical industry and power plants, including traditional and renewable energy sources. In applications with aggressive media, such as high-temperature, additive-rich water, replacement is necessary more frequently. But in general, our valves are very durable, provided they are properly maintained.
Mankenberg has been working almost paperless for some time now - in all areas of the company. Can you explain what digital solutions you implemented to achieve this and what challenges you had to overcome?
We have been using the same ERP system (Enterprise Resource Planning; editor's note) for 25 years and have aligned our processes with it. At the start of the coronavirus pandemic in spring 2020, we made our administration virtually paperless. This naturally resulted from the fact that not so many people were working in the company at the time and people were often working from home. Thanks to digitalization, we have significantly reduced the amount of paper we use - in administration alone, we save 150,000 sheets of paper every year, which corresponds to 60 boxes. We make similar savings in production. We also have a customer portal and recently introduced e-billing, which further reduces paper consumption. Since 2021, all of our products have had a QR code that enables access to digital documents.
But there are certainly still one or two exceptions.
Apart from occasional routing cards in the production area, our company is largely paper-free. Even training courses and personnel files are digitized. In our production, where we manufacture both components and valves, we are also virtually paper-free. The only paper documents that are still used are identification cards for load carriers. In addition, workstations are equipped with computers that provide all the necessary information.
How do you use digital technologies to increase the efficiency of your products?
Our customers can access comprehensive information, such as installation instructions and maintenance videos, via QR codes on the products. They can also order spare parts or maintenance kits directly from this digital environment. This is much more effective and sustainable than traditional paper instructions or printed order forms.
What is the feedback from customers?
Customer acceptance has been very good, especially since we had to introduce digital invoices. The customer portal significantly improves clarity and access to the necessary documents. All the changes have been well received by customers, as they make it easier to access information at any time.
What other advantages does digitization offer?
Access to digital documents is easier and faster for assembly and quality assurance. Large amounts of data no longer have to be sent by e-mail, but are available centrally. Digitally stored data allows us to access documents even after many years, which is often difficult with paper-based systems. This not only makes it easier to maintain old systems, but also to track who has accessed which information. Digital traceability gives us more precise insights into usage and interaction. This improves our data security and archiving capabilities and significantly reduces the administrative burden.
How does this affect production control?
Previously, changes had to be implemented manually and on site in production, which was inefficient. Now we can communicate changes digitally and immediately to the right place, which reduces errors and delays.
Apart from digitalization, what other sustainable initiatives have you implemented?
Since 2017, we have been implementing a funding programme for digitalization and sustainability supported by ERDF funds (European Regional Development Fund; editor's note). The initial investment was around two million euros. We have invested in energy-efficient machines and production processes, including converting our lighting to LED. We regularly carry out CO2 balancing and have been measuring our energy consumption per valve produced for three years. This is also supported by certification at company level.
Are there special training measures for your employees in relation to sustainability?
Yes, we hold regular training courses and have an integrated management system for occupational safety, environmental protection and health. We also promote awareness of sustainability through initiatives such as supporting local beekeepers.
How do you make your supply chain sustainable?
We source over 90% of our external materials from the region, which minimizes transport distances and improves our carbon footprint. Even though some components come from further afield, they only make up a very small proportion of our overall supply chain.
Given the economic challenges, how do you reconcile profitability with sustainability?
Digitalization and automation have enabled us to make significant savings, particularly by increasing efficiency in production processes. These improvements have allowed us to produce the same quantity with fewer staff and save resources at the same time. In fact, these technologies do not lead to additional costs. On the contrary, we save considerably by eliminating printing costs, for example. The conversion of our marketing from traditional print media to digital formats alone has resulted in a six-figure saving.
What plans do you have for the future in terms of sustainability?
We aim to further deepen our sustainability initiatives and constantly adapt our technologies to the requirements of the market and the environment. Our goal is to continue to be efficient and environmentally conscious while providing innovative solutions for the industry. One concrete goal is to improve our CO2 footprint both company-wide and product-related. We are planning our first certification in this area to find out how relevant it is for our customers and which standards they prefer.
What about the use of renewable energies in your production?
We have examined the economic viability of our own solar power system, but do not yet see any attractive conditions for implementing it. Nevertheless, we are keeping an eye on developments in the field of renewable energies.
And what's next for digitalization and automation?
Digitalization and automation are continuous processes. We are connecting previously independent systems and continuously optimizing our processes. Close cooperation with regional suppliers is also important for us, especially in times of crisis, in order to maintain the supply chain.
Are you also working with artificial intelligence (AI)?
Yes, we have already carried out test projects and are exploring how we can use AI to analyze our extensive databases. We see AI as support for improving the efficiency of our processes, not as a replacement for human workers. Above all, AI helps us to work faster and in a more structured way. In the future, we may use AI to determine the physical parameters of a control process and suggest optimal products to customers. Nevertheless, personal customer advice remains a central component of our service.
