Dec. 23, 2024
New pump facility in poland reshapes hygienic manufacturing
GEA’s facility in Koszalin, Poland, sets a benchmark in hygienic pump production. The multi-purpose site combines decades of German engineering expertise with advanced digitalization and scalable solutions. A bold step to meet the growing demands of industries like food, beverage and pharmaceuticals.
In November 2024, GEA welcomed customers, partners and employees to celebrate the launch of its latest pump production facility in Koszalin, Poland. This site, part of GEA’s vision for its “Factories of the Future,” that integrates low-emission practices, advanced automation and cutting-edge digitalization. In a market that MarketsandMarkets forecasts to grow from 9.4 billion euro in 2022 to 12.25 billion euro by 2027 for food and beverage applications alone, GEA’s new facility is more than a production site. Reflecting the company’s long-standing commitment to innovation in GEA Hilge hygienic pump manufacturing, this site is a strategic investment in resource and process-efficient and resilient manufacturing.
'Quality is at the heart of everything'
Visitors to Koszalin quickly saw what makes this facility special. Pierre Schmidt, Account Manager at CTRI France, a distributing partner of GEA Hilge since 1994, shared his impressions. “I was amazed by how modern this facility is,” he said. “The robotic operations and state-of-the-art CNC machines are impressive. You can immediately tell that quality is at the heart of everything.” He found the metrology lab in a cube located at the heart of the factory particularly interesting because it demonstrated that “digitalization is integrated from the engineering phase, right through to manufacturing, with complete monitoring of quality and production tracking as well as real-time data feedback.”
Digitalization is integrated from the engineering phase right through to manufacturing.
– Pierre Schmidt
Account Manager at CTRI (France)
A strategic response to changing customer needs
The establishment of the Koszalin facility also involves relocating production from Germany to Poland and takes more than logistics into account. It’s a response to shifting global dynamics in hygienic manufacturing. “This factory is part of a broader effort to stabilize supply chains and respond more quickly to our customers’ needs,” explains Karsten Becker, Vice President Business Line Hygienic Pumps. “Events like COVID-19 have disrupted supply chains around the world, forcing us to make supply chains more resilient so we can respond to our customers’ product trends quicker. Do you remember the Greek yogurt boom ten years ago or the hard seltzer trend five years ago? Today, we see new products appearing on supermarket shelves almost daily. Our markets are evolving rapidly, and as manufacturer, we need flexible, reliable solutions to keep up.”
That’s why GEA has reimagined its global production strategy, aiming high for digitalization and end-to-end supply chain visibility. In addition to relocating production to Koszalin, the business line launched the SalesPro e-commerce platform. GEA will also move the spare parts business to a central warehouse at the beginning 2025. Meanwhile, the pump experts will further develop Bodenheim, Germany, as a Center of Competence to steer the global pump business, ensuring that GEA’s engineering expertise and customer-focused innovation remain at the forefront.
“The biggest challenge today is indeed the changing customer behavior,” Yada Sirimanuwat from Vatska Company Limited in Thailand, confirms. “That, in combination with the supply chain optimization in China will definitely impact the market internationally. But this new facility in Koszalin will position GEA ahead of the curve in sustainability and long-term development.”
Balance between legacy and transformation
GEA’s market position in the pump business and its ability to make such a strategic pivot were no small undertaking to win. “Ask a brewmaster what he wants for his brewhouse, and the answer is likely a GEA Hilge pump,” says Becker. “Over the years, our pumps have evolved from being a trusted brand to a becoming a ‘love brand’ in hygienic manufacturing.” By prioritizing customer needs and aligning product development with real-world applications, GEA has cemented its pumps as industry staples across breweries, dairies and pharmaceutical plants.
The introduction of hygienic pump production in Koszalin reflects a delicate balance between legacy and transformation. Daniel Steingass embodies that balance. As a mechanical and welding engineer, he was responsible for the smooth, seamless design of GEA Hilge pumps. With his experience in industrial automation, Daniel prioritizes efficiency and high-quality craftsmanship. Today he is the new Head of Production in Koszalin.“Automated welding has been part of our process since 1989,” he says. “Koszalin’s greenfield site allowed us to rethink and redesign the production flow. For example, tasks once spread across three workstations are now consolidated into one step in Koszalin. Rest assured, the quality of every step in our single-piece production process remains uncompromised.”
MES, the backbone of Industry 4.0
Koszalin is powered by digital integration through a manufacturing execution system (MES – see fact box). “MES supports the concept of Industry 4.0,” explains Justyna Fudala, Digitalization Manager at the Koszalin site. “Koszalin is the fourth site to implement this system. MES allows better and faster communication between people on the shop floor, as well as with other divisions. We also use 3D glasses for training, quality control and on-demand support. The advantages for the customers are speed, agility and 100% traceability, which is of the utmost importance, particularly in the pharmaceutical industry.”
High-tech production meets engineering expertise
The partnership between the Koszalin production site and GEA’s Center of Competence in Bodenheim exemplifies the power of collaboration, seamlessly integrating cutting-edge manufacturing with expert engineering. This interdependent relationship enhances the efficiency and innovation of GEA’s global operations. Koszalin serves as the production hub, while Bodenheim is the center for innovation, customer collaboration, and technical excellence. From engaging with customers on new product and project development to delivering advanced training and offering comprehensive global service support, Bodenheim ensures that each pump upholds GEA’s legacy of reliability and quality while being perfectly tailored to the customer's application.
“This collaboration ensures that every pump we produce reflects German engineering excellence while being optimized for efficiency in a state-of-the-art environment,” says Jörg Scheid, Senior Vice President of Global Production. “To make this work, we invest heavily in training and creating strong connections to empower our teams to deliver excellence.”
Beyond pumps: a versatile facility in a global production network
The Koszalin facility is a cornerstone of GEA’s global production network. “This facility is one of our key multi-purpose factories,” says Jörg Scheid. “By supporting multiple divisions and leveraging advanced technology across product lines, we enhance our operational flexibility and resilience. This enables us to adjust production quickly, focusing resources where they’re needed most. Alongside Koszalin, we operate similar multi-purpose sites in China, and India, which manufacture GEA pumps and valves.” The Koszalin site exemplifies how GEA’s integrated production strategy strengthens its position in diverse markets, ensuring a robust and adaptable manufacturing framework to meet global demands.
GEA’s multi-purpose sites ensure a robust and adaptable manufacturing framework to meet global demands.
– Jörg Scheid
Senior Vice President of Global Production
This adaptability certainly resonates with customers like Pierre Schmidt, CTRI: “In today’s fast-paced world, we need to be able to find solutions that are both quick and adaptable. We have high hopes for this new production setup, which will undoubtedly be an asset for us as distributors, but, above all, for the end customer, who will benefit from a flexible system capable of delivering premium products very quickly.”
Resilience, customer trust, and a future-oriented view
As the global landscape of hygienic manufacturing continues to evolve, GEA’s new facility in Poland reflects the company’s commitment to adapting to change. At its core, moving the production of the GEA Hilge pumps to Koszalin and complementing the strengths of both sites now is a strategic evolution rooted in resilience, customer trust, and future-oriented goals. By integrating the legacy of pump engineering in Bodenheim with forward-thinking processes and innovations, GEA ensures that every pump meets the highest standards, the same dedication to quality, innovation and service that have defined GEA’s pump business for decades.
