We strive to be a reference,

Transcription

1 E N T E R I N G Y O U R W O R L D

2 We strive to be a reference, not just a name 9 Up on the hills about 0 km north-east of Lyons Paul Malerba and Jean-Jacques Dugelet started their metal-door-frame company, in Cours-la-Ville. 98 The firm diversified for the first time, going into metal door units for joiners working on housing projects. 989 The start of wooden-door making, for external expansion. 99 The range was diversified again, with the Technical Metal Doors (TMD) range, designed for metal locksmiths. 00 Bruno Malerba took over from his father. 009 Takeover of Menou, a firm specialized in standard wooden door units for the professional trade and DIY outlets. 00 Reorganization of the Technical Support Unit, and the Specifying Department. 0 Incorporation of Montibert, a company specialized in indoor fire-door solutions. 0 Expansion of MD into M-Center distribution points, veritable relays between factories for professionals.

3 Coil splitting in Factory A NOVEL INDUSTRIAL APPROACH 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 00,000 m nearly 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. MALERBA, SOME KEY FIGURES > Steel sheets,00 tonnes p.a. > Surface painting tonnes p.a. > Primary coats 0 tonnes p.a. > Wood-fibre panels,90,000 m p.a. [9 acres!] > Official fire-resistance reports awarded more than 0 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 SIDE To 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.

4 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 trademark is above all our reputation 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. Fire-resistant doors FASTE-rated indoor door units MARQUAGE Door units PORTE EXTÉRIEURE NF = Norme Française, the equivalent of BS, or ASA FASTE = Fire, Acoustics, Stability, Thermal, [forced]entry 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.

5 vilets horizontal DevDur:Mise en page 8/0/0 :0 Page A PROACTIVE ENVIRONMENTAL APPROACH Cette entreprise a fait certifier sa chaîne de contrôle. pefc-france.org PEFC: This company has had its control line certified. FSC: The mark of the Forest Stewardship Council 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 0% in less than ten years), VOC (Volatile Organic Compounds) down by 90% after modifying painting procedures between 00 and 008, recycling and optimizing raw materials, value-adding 0% of our factory waste, Lastly, thanks to a roof we have installed covered with photovoltaic cells we are also producers of 0,000 kilowatts of solar electricity per year. - Fabricant - Site de fabrication - Gamme de produit 4 - Description du produit - Fonction Avec Fiche Produit Bilan Environnemental vous, Malerba - Performances techniques s engage durablement L e s e n s d e l o u v e r t u r e 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, CO emissions, water consumption, air pollution, water pollution, etc. - Entretien / Maintenance 8 - Unité fonctionnelle 9 - Durée de vie typique These data, recorded on Environmental Product File Reports (FPBE), are used to validate the suitability of our products with sustainable construction projects (HQE, BBC, RT0, etc.). *Technical Association of Technical Door Manufacturers

6 Metal door frames 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 P0 P

7 METAL DOOR UNITS FOR HOUSING 4 Factory4 8 Welding robot 9 One of the profiling lines Speciality: Metal door frames Built in 9 Split coils Area: 0,000 m (.4 acres) One of the profiling lines Output capacity:,00 door frames per day Spot-welding the accessories One of the plate-bending presses 4 Welding robot Manual mounting workstation Fitting accessories on the line P Anti-corrosion treatment by dipping Removal from the oven prior to dispatching 8 9 P

8 Metal door units for Housing 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. Find out more about our most recent products P4 P

9 BLOCS-PORTES MÉTAL HABITAT 8 Factory 4 Stock of coated metal sheets Sheet metal punching Speciality: Metal door units for housing Built in 98 Stock of coated metal sheets Area: 0,000 m (.4 acres) Sheet metal punching Output capacity: 0 units per day One of the plate-bending presses Core bonding 4 Fitting plugs, pegs and locks The finishing touches the oculi and the mouldings One of the hook and toggle workstations P Pre-packing and pre-dispatch storage 8 P

10 Wooden door units for housing 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. Find out more about our most recent products P8 P9

11 Tertiary sector wooden door units: Offices, Education, Hotels, Culture 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. Find out more about our most recent products P0 P

12 Tertiary sector wooden door units: Health and Hospital Here, strictness is the rule: emergency, silence, performance? Our doors match patient and care-giver expectations directly. Find out more about our most recent products P P

13 WOODEN DOOR UNITS 4 Factory Composite robots for the anti-break-in and acoustic cores Speciality: Wooden door units for housing and the Tertiary Sector. Steaming and stabilizing the wood Built in 989 Composition robots for anti-break-in and acoustic cores Area: 4,000 m (.9 acres) Output capacity:,000 leaves per day Composition of solid laminated cores One of our machining workstations 4 Machining, closeup Intermediate storage, prior to finishing P4 P

14 WOODEN DOOR UNITS Factory cont. Positioning thermo-inflating joints and built-in accessories Dispatching orders Positioning thermo-inflating joints and built-in accessories Turning over to position the cover strips and the oculi 8 Placing the oculi 9 8 Placing pins and plugs 0 Monitoring traceability of orders in the factory Checking the laminated leaves before packing Checking the laminated leaves before dispatching P Tracking-labels for unit upgrading Dispatching orders 4 P

15 WOODEN DOOR FRAMES 4 8 Factory Factory DOOR FRAMES AND MENOU WOODEN UNITS Storage of raw materials Part of the facilities Storage of raw materials Speciality: Wooden door frames Speciality: Wooden door frames and units for the trade. Part of the facilities Delignification Built in 00 Built in 0 Storage of raw materials Packing and dispatching Area: 0,000 m (.4 acres) Area:,000 m (.9 acres) Delignification Output capacity: 00 door frames per day Output capacity:,000 door units per day Production monitoring 4 Assembling door units prior to pressing Robot distribution Hook and toggle P8 Assembling the frames View of the assembly line 8 9 P9

16 Technical Metal Doors 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. Find out more about our most recent products P0 P

17 DOOR UNITS AND TECHNICAL METAL DOORS 4 8 Factory Epoxy-cooking 9 0 oven Manual welding of frames Speciality: Door units and Technical Metal Doors Built in 99 Area: 9,00 m (. acres) Output capacity: panels per day 4 Punching Folding by press Manual welding of frames Painting Epoxy-cooking oven Core fitting Fastening accessories 4 /8 Installing pivots 9 P Quality Control Packing 0 P Pre-dispatch storage area

18 TECHNICAL METAL DOORS 4 9 Factory Automatic sheet-metal punching Speciality: Door units for emergency and service exits Built in 00 Area:,000 m (.48 acres) Output capacity: 00 door units per day Sheet metal cutting Automatic sheet-metal punching Assembly line Fastening accessories Fastening the split hinges Quality Control 4 P4 P

19 Vitreous products, hatches & sheath facades 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. Find out more about our most recent products P P

20 VITREOUS PRODUCTS, HATCHES & SHEATH FACADES 4 Montibert 9 Installing the glass 8 Closeup of finish 0 Speciality: indoor fire-door solutions Built in 0 Storage of raw materials Area:,00 m (.9 acres) PEFC-certified wood Output capacity: 0 fire-door products per day Overview Order scheduling office 4 Delignification Flow Assembly workshop P8 Installing the glass Closeup of finish 8/9 0 P9

21 Designed and produced by Jean Vasseur Communication Photos: Mod - J.F. Santoni - Studio Beaumont. This document is not binding; we reserve the right to modify details in the interest of product development January 04 Rue Paul Malerba Cours-la-Ville Tel.: + (0) Fax: + (0) info@malerba.fr