ENTERING Y OUR W ORLD - malerba.fr · Every Malerba door unit has an Environmental Product File...
Transcript of ENTERING Y OUR W ORLD - malerba.fr · Every Malerba door unit has an Environmental Product File...
We strive to be a reference, not just a name
1971Up on the hills about 70 km
north-east of Lyons Paul Malerba
and Jean-Jacques Dugelet started
their metal-door-frame company,
in Cours-la-Ville.
1982The firm diversified for the first time,
going into metal door units for
joiners working on housing projects.
1989The start of wooden-door making,
for external expansion.
1997The range was diversified again,
with the Technical Metal Doors (TMD)
range, designed for metal
locksmiths.
2005Bruno Malerba took over from his
father.
2009Takeover of Menou, a firm
specialized in standard wooden
door units for the professional trade
and DIY outlets.
2010Reorganization of the Technical
Support Unit, and the Specifying
Department.
2011Incorporation of Montibert,
a company specialized in indoor
fire-door solutions.
2012Expansion of MD into M-Center
distribution points, veritable relays
between factories for professionals.
AN INNOVATIVE APPROACH TO PRODUCTS
Heat, acoustic, fire and theft resistance, plus flood
protection… our door unit performances are constantly
being improved. To achieve that our Design Office has a
testing laboratory where potential new solutions worked
out with our clients are assessed upstream. Our aim is to
provide the best door units, ones that respond to today’s
building industry challenges.
ALWAYS BY YOUR SIDETo provide backing for our two sales
networks we have implemented a
Technical Support Unit dedicated to major
projects and studies of complex items.
Our intention is to play a very active role
in building matters by contributing —from
the drawing board—technical support that
enhances the overall quality
of end results.
> Steel sheets 12,600 tonnes p.a.
> Surface painting 37 tonnes p.a.
> Primary coats 102 tonnes p.a.
> Wood-fibre panels 3,790,000 m2 p.a. [936 acres!]
> Official fire-resistance reports awarded more than 250
MALERBA, SOME KEY FIGURES
In just two generations our company has become
a national benchmark in terms of doors for the
housing, tertiary, hospital and industry sectors.
To meet the growing demands of our clients—while
dealing with the varied applications of our products
—we have developed a unique industrial tool.
We have over 100,000 m2—nearly 25 acres, or a million square feet—of factories, storage areas and offices
around Cours-la-Ville where we began. To ensure maximum reactivity each unit has leading-edge technology
to guarantee flawless production, and meets the highest standards of quality and precision.
Also… to respond to building industry demands we have two thoroughly tried and tested logistics partners
specialized in delivering our products to building sites.
MADE IN FRANCE Our products are all made to order to meet the specific needs of each architectural project. To ensure the best
delivery times while strictly complying with prevailing building standards we have chosen to maintain our entire
production operation in France. This local approach between our various units means that we can combine
and share the high-level skills and know-how of all our operators.
A NOVEL INDUSTRIAL APPROACH
Coil splitting in Factory 2
CERTAINTY BEYOND STANDARDS To demonstrate compliance with
the standards and quality of our
products, we are committed to
numerous certifications in
partnership with the most reputable
organizations. We refuse all
compromise in matters of quality
and we guarantee each of our door
units. Our monitoring of regulations
goes hand in hand with our desire
to participate actively in the
development of good practices
in building sectors.
NF = Norme Française, the equivalent of BS, or ASA FASTE = Fire, Acoustics, Stability, Thermal, [forced]Entry
Our trademark is above all
our reputation
MAKING INNOVATIONS AVAILABLE Malerba products are on display in three show-rooms—two in Cours-la-Ville and one just outside Paris—that are also venues for technical exchanges and training sessions.
MARQUAGE
PORTE EXTÉRIE
URE
Fire-resistant doors
FASTE-rated indoor
door units
Door units
EVER BETTER CONTACTS WITH PROFESSIONALS In order to better respond to demands, we have
organized our sales networks into areas of
expertise. Carpenters and joiners, locksmiths
and metal-workers, general contractors, but also
designers and contracting authorities—they all
have access to regional support and help, from
the drawing board through to the reception of
programmes. These help-providers rely on the
skills of the Design Office personnel, together
with the Technical Support Unit to ensure
the best harmony between needs and products.
Our company is located in some beautiful surroundings where we have always sought to respect the environment. Our present sustainable development policy comes to life in practical terms through all the elements of our organization.
Products: each product line has a data-sheet spelling out its environmental impact.
Certification: we hold both PEFC and FSC certificates, for our procurements and and the production of our wooden door units.
Regulations: when the ATF-BTP* professional association was created as part of the FIBC (Federation de l’Industrie Bois Construction), we became involved in many standards and regulatory issues. In particular we work on the creation of joint schemes so as to draw up Environmental Product Declaration (DEP) sheets common to manufacturers of wooden door units, whether solid or with windows, or glazed frames.
Infrastructures: all our facilities meet the most stringent requirements and standards. To improve the environmental results of our activities we have multiplied our initiatives:• our wood factories are equipped with heating equipment
to recycle the chips generated in manufacturing,• energy-saving steps in the production units—
high-performance machines are chosen, with variable speed systems, etc,
• water consumption and pollutant discharges reduced (cutting water consumption by 50% in less than ten years),
• VOC (Volatile Organic Compounds) down by 90% after modifying painting procedures between 2001 and 2008,
• recycling and optimizing raw materials, value-adding 70% of our factory waste,
Lastly, thanks to a roof we have installed covered with photovoltaic cells we are also producers of 110,000 kilowatts of solar electricity per year.
*Technical Association of Technical Door Manufacturers
A PROACTIVE ENVIRONMENTAL APPROACH
10-31-2004
Cette entreprisea fait certifier sa
chaîne de contrôle.pefc-france.org
Avec vous, Malerba s’e
ngage durablement
L e s e n s de l ’ o u ve r t u re
3 vilets horizontal DevDur:Mise en page 1 18/03/10 17:05 Page 2
Every Malerba door unit has an Environmental Product File Report
The life cycles of all the types of Malerba products—wooden doors, metal door units, Technical Metal Doors, and frames—have been analysed. These studies have enabled quantified diagnoses to be made of the environmental impacts
of our ranges of products—energy consumption, CO2 emissions, water consumption, air pollution, water pollution, etc.
These data, recorded on Environmental Product File Reports (FPBE), are used to validate the suitability of our products with sustainable construction projects (HQE®, BBC, RT2012, etc.).
Fiche Produit Bilan Environnemental
1 - Fabricant
2 - Site de fabrication
3 - Gamme de produit
4 - Description du produit
5 - Fonction
6 - Performances techniques
7 - Entretien / Maintenance
8 - Unité fonctionnelle
9 - Durée de vie typique
PEFC: This company has had its control line certified. FSC: The mark of the Forest Stewardship Council
Met
al d
oor f
ram
es
Metal door frames are what have really built the reputation
of our business. Whether made by profiling or by folding,
their standard manufacture includes high-performance
anti-corrosion treatment. They are available pre-painted
or with a lacquer finish, but always Malerba-signed quality.
Find out more about our most recent products
P11P10
Speciality: Metal door frames
Built in 1971
Area: 10,000 m2 (2.47 acres)
Output capacity: 2,500 door frames per day
Split coils
One of the profiling lines
Spot-welding the accessories
One of the plate-bending presses
Welding robot
Manual mounting workstation
Fitting accessories on the line
Anti-corrosion treatment by dipping
Removal from the oven prior to dispatchingP13P12
Factory4
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TA
L D
OO
R U
NI
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FO
R H
OU
SI
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Met
al d
oor u
nits
fo
r Hou
sing
Our metal door units are the best guarantee of
safety and comfort. Long admired for their
technical qualities, they are now also available with
novel finishes in tune with current building trends.
P15P14
Find out more about our most recent products
Stock of coated metal sheets
Sheet metal punching
One of the plate-bending presses
Core bonding
Fitting plugs, pegs and locks
The finishing touches—the oculi and the mouldings
One of the ‘hook and toggle’ workstations
Pre-packing and pre-dispatch storageP17P16
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Speciality: Metal door units for housing
Built in 1982
Area: 10,000 m2 (2.47 acres)
Output capacity: 550 units per day
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Stock of coated metal sheets Sheet metal punching 21
4 7Factory
Whether in new or renovated buildings our wooden door
units blend in with all indoor and outdoor schemes. Their
success is like their composition: sustainable.
P19P18
Woo
den
doo
r uni
ts
for h
ousi
ng
Find out more about our most recent products
Work also involves sharing space and facilities. Our door
units contribute to harmony in shared spaces, while
maintaining the comfort of each person, and guaranteeing
compliance with all building standards.
P21P20
Terti
ary
sect
or
woo
den
door
uni
ts:
Offi
ces,
Edu
catio
n, H
otel
s, C
ultu
re
Find out more about our most recent products
Here, strictness is the rule: emergency, silence, performance?
Our doors match patient and care-giver expectations directly.
P23P22
Terti
ary
sect
or
woo
den
door
uni
ts:
Hea
lth a
nd H
ospi
tal
Find out more about our most recent products
P25P24
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WO
OD
EN
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OR
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IT
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Steaming and stabilizing the wood
Composition robots for anti-break-in and acoustic cores
Composition of solid laminated cores
One of our machining workstations
Machining, closeup
Intermediate storage, prior to finishing
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Speciality: Wooden door units for housing
and the Tertiary Sector.
Built in 1989
Area: 24,000 m2 (5.93 acres)
Output capacity: 3,000 leaves per day1
Composite robots for the anti-break-in and acoustic cores 2
Factory
P27P26
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OR
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Positioning thermo-inflating joints and built-in accessories
Turning over to position the cover strips and the oculi
Placing the oculi
Placing pins and plugs
Monitoring traceability of orders in the factory
Checking the laminated leaves before packing
Checking the laminated leaves before dispatching
Tracking-labels for unit upgrading
Dispatching orders
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Positioning thermo-inflating joints and built-in accessories Dispatching orders 15
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Factory
Part of the facilities
Storage of raw materials
Delignification
Production monitoring
Assembling door units prior to pressing
Robot distribution
‘Hook and toggle’
Assembling the frames
View of the assembly line
Storage of raw materials
Delignification
Packing and dispatching
P29P28
WO
OD
EN
DO
OR
FR
AM
ES
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DO
OR
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AM
ES
AN
D M
EN
OU
WO
OD
EN
UN
ITS
Factory
Speciality: Wooden door frames
Built in 2006
Area: 10,000 m2 (2.47 acres)
Output capacity: 500 door frames per day
Speciality: Wooden door frames and units for the trade.
Built in 2012
Area: 12,000 m2 (2.97 acres)
Output capacity: 2,000 door units per day
Factory
Our Technical Metal Doors are at home in all types of industrial
environments: they have many optional features and technologies
that can be adapted to all your requirements.
P31P30
Tech
nica
l Met
al D
oors
Find out more about our most recent products
Punching
Folding by press
Manual welding of frames
Painting
Epoxy-cooking oven
Core fitting
Fastening accessories
Installing pivots
Quality Control
Packing
Pre-dispatch storage area
P33P32
DO
OR
UN
IT
S A
ND
TE
CH
NI
CA
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ET
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DO
OR
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Factory
Speciality: Door units and Technical Metal Doors
Built in 1997
Area: 9,600 m2 (2.37 acres)
Output capacity: 135 panels per day
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Sheet metal cutting
Automatic sheet-metal punching
Assembly line
Fastening accessories
Fastening the split hinges
Quality Control
P35P34
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CH
NI
CA
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ET
AL
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OR
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Factory
Speciality: Door units for emergency
and service exits
Built in 2010
Area: 6,000 m2 (1.48 acres)
Output capacity: 100 door units per day
Vitre
ous
prod
ucts
, ha
tche
s &
she
ath
faca
des
Montibert—a company specialized in fire-door solutions
inside buildings—is now part of the Malerba range on offer.
Developed in synergy, the Malerba and Montibert products
perfectly complement and enrich each other while conforming
with the strictest standards.
P37P36
Find out more about our most recent products
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Storage of raw materials
PEFC-certified wood
Overview
Order scheduling office
Delignification
Flow
Assembly workshop
Installing the glass
Closeup of finish P39P38
Montibert
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TR
EO
US
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OD
UC
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AT
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& S
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AT
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AC
AD
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Installing the glass Closeup of finish 109
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Speciality: indoor fire-door solutions
Built in 2012
Area: 7,700 m2 (1.9 acres)
Output capacity: 130 fire-door products per day
www.malerba.fr Rue Paul Malerba - 69470 Cours-la-Ville Tel.: +33 (0) 4 7489 8585 - Fax: +33 (0) 4 7489 8257 - [email protected]
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