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alongside his father in the production contributing incrementally to productivity and capacity, which ensures, again, that production
operation. Giampietro Bernabeo’s daughter quality control. Smaller diameter products are is not interrupted if repair is necessary. Beneri
Patrizia is joint managing director with her ejected from the presses into a rotating bin is geared entirely to produce economic
brother, mainly responsibility for export sales system – segmented rather like an orange. batches, a key reason for supplying the market
and commercial matters. Her husband, This ensures the regular inspection of small through experienced and committed
Alessandro Limonta, also works in the business batches as well as limiting the weight the distributors and, also, for concentrating
with responsibility for logistics to the Italian operator must handle when product is tipped virtually exclusively on DIN standard products.
market. into a larger bin, ready for heat treatment. A few hundred metres away is Beneri’s
In total 78 people work in Beneri – Larger diameter retaining rings are fed onto a heat treatment facility. Three lines, again,
generating sales of around 20 million euros in dismountable bar, clearly marked to designate ensure ample capacity to ensure production is
2008. As the business grew, expansion on a the batch quantity. The operator removes the uninterrupted during maintenance. The first
single site became impossible. Instead the bar and inserts two securing wires through the line is a continuous mesh belt, controlled
company now has four distinct but closely holes on the retaining rings. For the atmosphere hardening furnace feeding into an
linked locations in Valmadrera, each remainder of production the
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specialised and optimised to ensure the rings will remain
highest levels of efficiency. The main ‘assembled’ in this
production facility houses two distinct way, eliminating
operations. One produces smaller sizes of tangling and also
retaining rings and washers from steel strip, ensuring that they
using high speed mechanical presses – ranging are correctly
from 60 to 125 tonne. The presses are fitted oriented for final
with process monitors, the latest using new packaging. The
technology controlled from a digital concept is simple
workstation. For zero-defect requirements but one that
DIMAC inspection machines use two cameras required vision to
to check dimensions and a laser to check for deliver both
deformation. efficiency and
Larger diameter rings, from 30mm upwards, quality.
are produced in an adjoining area using In total some
trapezoidal wire, fed into two stage machines. 1,200 individual
The first stage is a coiler creating the circular tools are used in
shape, the second a 40 or 80 tonne press production. For
which forms the inner profile of the clip and popular sizes two
punches the holes. The very largest rings, up tooling set-ups are
to 300mm diameter, are produced on slow retained to ensure
speed presses with rotating tooling tables. there is no break
Each operator is responsible for three in production if
machines and his own quality control, regrinding or
underpinned by an overall random sample cleaning is
inspection regime. Throughout the production required. Beneri
environment small but often crucial examples has also
of the Bernabeo family’s insight to the consciously invested
production process are to be seen – each in machine over
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