EXTRAORDINARY EXCAVATORS

Komatsu Mining from Benrath is one of the world market leaders in the field of machines for the mining industry. 

When one of the products manufactured at the Komatsu plant in Düsseldorf is completed, unusual activities start to happen in the district of Benrath. The excavators made by Komatsu are so huge, that they can only be transported in parts. 18 low loaders, carrying tons of weight, usually leave the factory grounds at Forststraße at night and, moving at a steady pace for about 20 minutes, reach the Reisholz river port. There the heavy goods are loaded onto a vessel. Along the river Rhine the journey initially leads towards the international ports of Rotterdam or Antwerp, and from there eventually across the world.

“WE HAVE ALL THE CORE SKILLS, THAT ARE NECESSARY FOR THE PRODUCTION OF HYDRAULIC EXCAVATORS, ON-SITE.”

The reason for this is that the Düsseldorf-based mining division of the excavator manufacturer Komatsu is entirely aimed at international trade. “We actually have no customers in Germany,” states Ralf Petzold, chairman of the board. Yet the excavator manufacturer in Benrath is one of the global market leaders within the mining industry. The high-performance machinery can be found in mines across the continents. The development and manufacture takes place at the plant in Forststraße - and also logistic, maintenance, services and spare parts are being handled at Komatsu’s headquarters in Düsseldorf. “We have all the core skills, that are necessary for the production of hydraulic excavators, on-site,” explains Petzold.

The plant location in Benrath has always been a place of innovation. The first ever entirely hydraulic excavator was manufactured here at Forststraße in 1954. In 1986 the predecessor company, Mannesmann-Demag, was the first manufacturer worldwide to build an ultra-large hydraulic excavator weighing about 500 tons. When Mannesmann-Demag became a mobile phone provider in 1996, it was joined by the Japanese company Komatsu, a leading manufacturer of construction equipment, which eventually took over the business a couple of years later. Its Japanese parent company produces the entire range of machinery and vehicles required for all applications in the construction and mining industry.

PC8000

• Can be used with its bucket to lift up to 90 tons of rock.

 • The excavator operator sits eight meters above the ground. 

• The bucket, with 42 cubic metres, has the size of a one-room flat. 

Komatsu in Düsseldorf is still producing some of the world’s biggest and most modern excavators. The company offers five different types to its customers. The biggest excavator, the PC 8000, has an operating weight of 760 tons. Two engines supply a power of 1500 kW each. The PC 8000 can move up to 90 tons of rubble. The driver is actually seated 8 metres above ground. And with its capacity of 42 cubic metres, the actual bucket has a size of a one bedroom flat.

It is easy to continue with the list of superlatives, but it is equally as interesting to take a look at the different skills, which the 800-strong workforce contributes to the company. “We are specialists in the processing of specialty steel,” explains Ralf Petzold. In order for the excavator bucket to withstand the use on extremely hard rock over a period of time, it is necessary to use special welding and tempering procedures. “The highly skilled welders that we require we train ourselves in order to guarantee a superior quality,” explains the chairman of the board. Moreover, most of the electrical assembly for the highly specialised machines takes place in Benrath, too. “Düsseldorf and its catchment area stands out as a location where we can recruit expert personnel,” claims Petzold, “it is, however, becoming increasingly difficult.” This is one of the reasons Komatsu works closely together with schools in order to inspire students to enter one of these professions. There are about 40 apprentices working in the company’s training workshops, studying to become electricians and technical product designers as well as industrial-, cutting- or construction mechanics.

Impressive size comparison: Ralf Petzold, CEO, next to a PC400.

In addition, there is a team of about 80 engineers who are working on new ideas with regards to hydraulic excavators, as nowadays the use of even the goliath of excavators in mining requires more than just sheer power. Although the excavators’ looks haven’t changed much, it is on the inside where the giants have been changing into high tech machines, densely filled with the latest technology. Digitalisation is playing an increasingly important role in the mining industry. Nowadays, the operator can read with the supplementary system on the digital display how much bulk is already inside the bucket. A number of sensors transmit the excavator’s data to the service team in Düsseldorf via satellite. This way it is easier to supervise the state of the machine and to reduce down-time of the equipment. Despite the extreme wear and to some extent extreme climate conditions, the machines reach a working life of about 15 years. Some Komatsu excavators have even been around for more than 30 years. A sign for quality products.

E-powered driving systems are on the rise in the mining industry, too. Petzold explains that the reduction of emissions is a matter of importance for mining companies. In the case of the giant excavators electric engines actually meet the unique power requirements. “The bigger the machines get, the more we see diesel engines being replaced by e-power,” says Petzold.

The developers should always be some years ahead of their clients, Petzold states. He adds: “Developments in technology are constantly taking place.” The automation of routine processes, for example, is aimed to relieve the pressure on excavator operators on a daily basis. Komatsu’s idea of autonomous vehicles rolling through mines has already been adopted. In the future, the trucks weighing several tons, which drive the material in the mine from the excavator to the next processing stage, could be entirely computer-operated. The development department in Düsseldorf-Benrath is already working on the digitalisation of the next generation of excavators to make their use even safer and more effective in the future. • 

Komatsu Germany
Forststraße 29
40597 Düsseldorf 
Germany

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FACTS

• Komatsu ist der zweitgrößte Baumaschinenhersteller der Welt. 

• Komatsu hat mehr als 1100 Großhydraulikbagger (>250 Tonnen) ausgeliefert

• Zur Komatsu-Gruppe gehören konsolidiert 258 Unternehmen.

• Komatsu verfügt über ein weltweites Service- und Fertigungsnetzwerk. Wenn das Düsseldorfer

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Words: Rainer Kurlemann
Pictures: PR

BICYCLE BOOM

Cycling - especially with electric assistance - is becoming increasingly popular. VIVID has talked to cycling specialists from Düsseldorf about the coronavirus' contribution to this development and what the most important bike trends currently are.

Over 3,2 million bicycles and e-bikes were sold in Germany in the first half of 2020. According to the Zweirad-Industrie-Verband ZIV, the two-wheel industry association, this is an increase of almost 10 percent compared to the first half of 2019. More than a third of these bikes had an electric motor - an increase of almost 16 percent. A booming business despite the corona pandemic! Or because of it?

“The bicycle trade in this country has never experienced this before, especially not over such a short period of time,” comments Marcel Hollenberg, Marketing & Retail Manager at Giant Germany. The world’s largest bicycle manufacturer from Taiwan has its German headquarters in Erkrath and runs a 700 square metre flagship store in Düsseldorf-Friedrichstadt - Giant Cycling World. “This year, many people have given up holiday trips to faraway places and invested their money in other things instead. For example, in a nice new bicycle or e-bike,” says Hollenberg. But even independently of the corona pandemic, the industry has been experiencing a strong tailwind in recent years. Especially due to the dynamic development of the e-bike from the “pensioner’s bike” with auxiliary engine to the stylish “Bicycle 2.0” that is a desirable status symbol.

However, the German bicycle trade also had to close its shops for several weeks in March 2020, which initially meant a drop in sales. “During this time, we hardly delivered any bicycles to the retail trade. Many of our retailers improvised and demonstrated bikes to their customers in the shop via Facetime or WhatsApp, for example. The purchase was then processed online and delivery to the customer's home was contactless,” Hollenberg recalls. Since then, the Giant team in the sales and service department has been operating partly from home, which works well.

Since bicycle repair shops were classified by politicians as “system relevant”, many dealers were able to generate at least some turnover with this service during the lockdown. Like Anja Bergen, Store Manager at Awsum. The concept store in Düsseldorf-Flingern opened its doors at the end of 2017 and does not only sell bicycles, but also cycling gear and accessories that have been tested and approved- true to the slogan “Things we love”: for example, bicycle shorts and jackets, shoes etc. In a short time, Awsum has continuously expanded its brand portfolio and is now, for example, the second largest retailer in Germany for the cult Berlin bicycle brand Schindelhauer and for the Spanish e-bike manufacturer Desiknio.

A look into awsum, a concept store for urban mobility in Düsseldorf-Flingern.

The gravel bike is super popular - here a top gravel bike - Revolt Advanced Pro by Giant.

“Since the reopening of our store at the end of April, we have been experiencing a real boom in sales. Many people who come to us, have really got to grips with cycling for the first time ever over the last few months,” says Anja Bergen. She cleverly anticipated this development and bought many bikes as well accessories early on, so that Awsum has been able to cushion the increased demand well so far. In the meantime, orders are slowly levelling off. “But there are things that are not delivered at all or only trickling in - helmets for example”. Many bicycle components, gear shifts or brakes, for example, are also manufactured in Asia, so there are delivery delays. “Because we are still relatively small, we sometimes have to juggle various aspects of our business, e.g. our way of organisation and service or how we stock our warehouse,” explains Anja Bergen.

Even the world’s largest manufacturer, Giant, is currently not immune to supply bottlenecks. But it has a decisive competitive advantage over other suppliers: “We are one of the few bicycle brands in the world that has everything from its own aluminium plants to its production facilities in one hand. This gives us a certain independence. But when it comes to components such as brakes or gears, we depend on suppliers as well,” explains Marcel Hollenberg.

What customers are increasingly asking for at the moment is in line with the major trends of the last two or three years. “E-bikes are becoming more and more stylish and delicate, which is also of great appeal to young people. This development will continue in such a way that in a few years the normal bike - we are talking about bio-bikes - will lead a niche existence compared to e-bikes”, Hollenberg states confidently. In addition, many people have rediscovered the racing bike as a sports object in corona times. The gravel bike - a more robust form of racing bike that is also suitable for off-road terrain - is also becoming increasingly popular.

“THIS DEVELOPMENT WILL CONTINUE IN SUCH A WAY THAT INA FEW YEARS THE NORMAL BIKE- WE ARE TALKING ABOUT BIO-BIKES - WILL LEAD A NICHE EXISTENCE COMPARED TO E-BIKES”

Looking ahead to the near future, David Eisenberger, Head of Marketing & Communication of the German Two-Wheeler Industry Association, is cautiously optimistic: “Bicycle mobility is systemically relevant. The last few months have shown that. Furthermore, we know that this year bicycle and e-bike have also attracted new target groups. Many of these new users will not want to do with-out two-wheel mobility even after the crisis”. •

Awsum has bikes of the cult brand Schindelhauer among others in stock, here the model LUDWIG XIV in midnight blue.

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Words:  Tom Corinth
Pictures: PR

SUPERMARKET IN YOUR POCKET

Online delivery services for food are not very popular in Germany. The Dutch provider Picnic has nevertheless succeeded in conquering the market in North-Rhine-Westphalia (NRW). VIVID spoke with Frederick Knaudt, Founding Team Picnic Germany, about a completely new business model. 

For many employees and families, food shopping is stressful - Germans spend an average of 20 working days a year on it, covering around 900 kilometres in their cars. A circumstance that inspired Dutch software developers Joris Beckers and Frederik Nieuwenhuys to come up with an innovative business idea: an app that allows you to have food delivered to your home, at the lowest possible price and without extra delivery charges. The result is called Picnic and has been on the Dutch market since 2015 continuously growing into a successful business model. Therefore, the they decided to expand into the neighbouring country in 2018. They chose Neuss and Düsseldorf as their location and brought Frederick Knaudt into their Founding Team Germany, who previously gained experience in various start-ups and as a founder in the food segment. “What immediately convinced me about Picnic was the objective of making food online affordable for everyone,” he says. Free delivery, and the same prices as in the 

The market has huge potential. In 2019, German food retailers generated a total turnover of around 125.3 billion euros, but online the situation is different at present: Although food has the highest percentage growth here, it only has a total market share of 1.4 percent. “The online food market is only just developing or we are developing it. And since 80-90 percent of customers in Germany have never ordered food online, we see many opportunities,” says Knaudt

Picnic’s two large refrigerated warehouses in Viersen and Herne receive fresh goods every morning.

And Picnic tries to make full use of this. “We do not run supermarkets and therefore save a lot of money. Nevertheless, logistics chains are all about efficiency at every point”. The two large cold storage facilities of the online supermarket are located in Viersen and Herne. These are supplied with fresh goods every morning, which are then delivered to a total of 14 hubs in the region. From here the orders are then sent directly to the 130,000 registered customers in Germany. 

“FROM THE START, WE HAD THE LUXURY OF BEING ABLE TO RETHINK EVERYTHING. THAT’S WHY WE ALSO BUILT OUR OWN CAR.”

At Picnic, efficiency at every point of the logistics chain is a top priority. This also applies to the loading of the delivery vehicles.

“We work according to the milkman principle: no individual appointments, but fixed schedules within which more customers in the same neighbourhood can be supplied within a time window of just 20 minutes,” explains Frederick Knaudt. This concept is a unique selling point of Picnic. “From the start, we had the luxury of being able to rethink everything. That’s why we also built our own car”.The vehicles developed by Picnic itself are electric, only 1.35 m wide and have a roller blind integrated in the side wall to enable goods to be removed as quickly and easily as possible. Picnic is also going its own way when it comes to the product range. The company offers the same products as a fully stocked supermarket. “However, customers bring in their wishes and thus contribute to the product selection”. The range of products on offer therefore remains dynamic and includes many regional and seasonal offers. A so-called low-price guarantee applies to pricing: the company constantly compares its prices with those of its competitors and then adjusts to the cheapest price.

Frederic Knaudt, Founding Team Picnic Deutschland

E-vehicles, product ranges designed by customers and highly dynamic prices are not the only innovations at Picnic. What else makes the online supermarket a future-oriented business model? “At Picnic you order food solely on your smartphone, and that makes the most sense for us. Picnic is like a supermarket in your pocket with which you can shop conveniently from wherever you are”. In addition, the delivery service succeeds with its concept of avoiding food waste. “Our customers can order for the next day until 10 p.m., which enables us to place very specific orders, e.g. with the baker. By the time the baker delivers his bread to us, we have already sold it,” says Frederick Knaudt happily. In cooperation with suppliers, the company is also increasingly trying to avoid plastic packaging and to switch to paper bags, for example. 

Picnic currently delivers in a total of 38 cities and exclusively in NRW, “but we are growing slowly and continuously,” says Knaudt. During the lockdown, the company was able to more than double the number of its registered customers. At times, 90,000 households were on the waiting list. “The nice thing is that these customers stayed with us!” The company’s location in Neuss and the headquarters in Düsseldorf also has not changed since its foundation. “We have a great environment and a good infrastructure here. That’s why the location remains ideal for us,” Frederick Knaudt says confidently. •

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Words:  Tom Corinth
Pictures: PR