HIGH
DEMAND
The BRUSS Production System (BPS) is an important building block in our areas of expertise.

Individually customized

Production at BRUSS

One of the decisive factors here is a functioning lean management system in which we define an effective and efficient design of the value chain. We use aspects of the lean philosophy such as "Go to Gemba" to make problems visible directly on site and thus continue to develop transparently and successfully.

Our principles at BPS

Our way of working is based on a special self-image: we manufacture our products to customer specifications, deliver "just in time" and focus on high quality with "Jidoka". In accordance with the Japanese principle of "Muda", literally translated as "no waste", we concentrate on minimizing negative influencing factors. But we also rely on the equally Japanese principle of "kaizen", which provides for small, gradual changes over time.

We develop suitable production processes for our customers with an "all-service offer". Customer specifications are our top priority, which we implement with standardized process monitoring and the right degree of automation. With innovative production technologies, structured processes and vertical integration of all business processes, we are one of the leading suppliers of sealing solutions for the automotive industry.

The starting point for every production process is the selection of the right material and a suitable process. Depending on the application and requirements, different materials such as rubber or elastomers are used. We determine the appropriate parameters in close consultation with our customers. Our production department at BRUSS monitors the entire process to ensure precise, high-quality processing and quality.

This includes leak tests, temperature and pressure resistance tests and mechanical load tests. The production department ensures that only seals that meet the high quality standards are used.

Features of production at BRUSS:

  • Industry 4.0
  • Customized products according to customer requirements
  • Close monitoring of the production chain
  • Automated processes
  • Use of innovative production technologies
  • Statistical process monitoring
Assemblies made of plastic, metal and seals

From the initial idea to series production, we take over the design of complete assemblies, including design sovereignty and warranty. As a customer, you receive a completely finished module according to your specifications, which covers the function you require over its entire service life, including the need for spare parts.

  • Hot gas and infrared
  • Hot rivets
Material and bonding system development

Checking existing materials or developing new ones is the task of our materials developers in collaboration with our chemical laboratory. Our expertise includes:

High-performance elastomers: focus on heat- and oil-resistant polymers, including fluoroelastomers (FKM) and other high-quality rubber types in more than 150 formulations.
Thermoplastics: engineering plastics such as PA6, PA66, as well as high-performance polymers such as PPA, PPS.
PTFE compounds: tailor-made solutions, especially for dynamic sealing systems.

We answer the question of whether a material is suitable in terms of function, specification fulfillment, processing and costs. The selection is always made in consultation with our customers, the development team and the processing production facilities. Testing takes place in our own laboratory through media storage and ageing. Series-accompanying tests for technical cleanliness are the order of the day.
If a combination of elastomers with strength carriers made of metals such as steel, aluminum or thermoplastics or PTFE is required, we select the appropriate bonding agent systems. We have decades of experience in this area and are well networked with the relevant suppliers.

Always at the cutting edge of market trends, we are constantly developing our skills, whether for adhesion to stainless steel, titanium, copper or other surfaces.

Carrier part pre-treatment

Where functionally required for a sealing component or module, material-locking connections can be developed with a wide variety of hard/soft components. A number of innovations have been developed based on this core competence of BRUSS. The development of bonding agent systems and coordinated surface treatment processes such as phosphating, various thin-film processes, plasma or laser pre-treatment are successfully interlinked. These process steps are almost always carried out on site in BRUSS' own production area, which is why all relevant plants have these production facilities. Our production standards enable the timely traceability of the process steps.

Elastomer production

In the field of elastomer materials, BRUSS successfully bridges the gap between development and production. The formulations developed in the chemistry laboratory are tested and optimized with the employees responsible for the processes in the respective processing departments before they are implemented in series production. If not yet standardized, this takes place at the latest during product development.

All technical precautions for optimum quality and traceability are in place, as are state-of-the-art mixing units. Compulsory incoming goods inspections and in-line tests enable defects to be detected at an early stage. However, this is no substitute for human expertise, which is the decisive factor for perfection in providing the customers of the entire BRUSS Group with the ideal elastomer compound in the long term.

  • Own mixing plant
  • Tool design and construction
  • Materials:
    • ACM
    • AEM
    • FKM
    • NBR
    • HNBR
    • EPDM
    • FVMQ
    • LSR
  • Properties:
    • Magnetic
    • Flame resistance
    • Various anti-friction coatings
    • Color coatings
Plastic injection molding
  • Design and toolmaking
  • From micro injection molding 0.1 g to hood base bodies with up to 3 kg
  • Insert parts
  • Further processing into complex assemblies
  • Large selection of electro-compatible, hydrolysis-resistant or flame-retardant materials (e.g. PA6, PA6.6, PPA, PPS, PBT, PP, POK)
  • With EVM shielding
  • Thermoplastics CO2-reduced
  • Thermoplastics for laser welding
PTFE sealing element production

Due to its temperature and oil resistance, PTFE is the sealing material of choice for radial shaft seals or shaft earthing modules, for example. At BRUSS, we decided several years ago to manufacture PTFE sealing elements in-house in order to be able to directly influence quality, innovation potential and costs. The necessary PTFE compounds are purchased from qualified companies with whom we have long-standing relationships.

The PTFE powder is pressed, sintered, cut and activated in-house in a process developed by us - thanks to our highly automated billet press, temperature-monitored sintering ovens, specially equipped lathes and our own activation system. The activation process etches the PTFE surface and enables chemical bonding with other materials. Taking into account the latest production and environmental criteria, we have thus succeeded in producing everything from PTFE compounds to sealing components under one roof, which is unique in the world.

  • In-house PTFE production (e.g. pressing, sintering, cutting and embossing)
  • Flexible design
  • High standard of quality control in all production steps
  • Bonding of PTFE to copper, plastics, steel, aluminum, titanium, PA and PPS
Surface technology
  • Surface treatment for bonding elastomers
  • Copper, plastics, steel, aluminum, titanium, PA, PPS
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