Industry & craftsmanship
The processes and procedures in the highly flexible industrial manufacturing facilities have been optimized. They go hand in hand with the employees’ skills as craftsmen – almost all are carpenters or wood mechanists by trade. Only this combination guarantees a level of quality that meets Duravit’s exacting standards.
This complex manufacturing process starts in the automated panel store, where storage of the raw material is computer-controlled. In production control, customer orders are grouped by material type to enable efficient manufacture with as little waste as possible. The resulting cutting plans enable the raw panels to be allocated to various cutting lines in the prefabrication phase. The components are then formatted and edged on the formatting line. Next stop is one of the processing centers, depending on the component in question. This may involve working steps from milling through drilling and sawing up to gluing shaped edges. Some of the components make a detour into the paint shop, where they are first pre-sanded, then painted – and also polished if required.
Final assembly of the furniture takes place in several stages depending on the specific order: for instance, custom construction holes are drilled, furniture fastenings applied or drawers fitted in production cells or on production lines – until the finished furniture is ready for final inspection and packaging.
Consoles, c-bonded and f-bonded solutions, Starck bathtubs, and mirrors and mirror cabinets that require significantly more manual input are manufactured in production cells in one complete pass.
Design & technology
At Duravit, the consistent design language goes way beyond the individual products in the bathroom. The development processes for ceramics, bathroom furniture and bathtubs run in parallel and come together to create the overall design. The employees in Product Management and Development are always working on tomorrow’s trends and innovations with external designers. This gives rise to new challenges such as the c-bonded technology, a process unique anywhere in the world that almost seamlessly combines the ceramics with the bathroom furniture. Such complex and unique innovations are the result of years of experience and expertise.
Overall, the bathroom furniture range at Duravit comprises seven programs that are designed to match a specific bathroom series, and six further bathroom furniture ranges that can be flexibly combined with multiple ceramic series.
As a rule, all furniture is manufactured specifically per order to meet the customers’ requirements. With 46 different surfaces available – décor, wood or lacquer – the possible variations are endless.
Quality & sustainability
Duravit places great importance on the highest possible quality when selecting the materials to use: suppliers of laminated panels, real wood veneers, lacquers, ABS edges, fittings or lighting are carefully chosen and longstanding partners. Each completed piece of furniture is subjected to a 100% quality inspection regarding functionality, processing and surfaces.
The development process also involves comprehensive tests in the in-house climatic chamber to ensure that the furniture and materials can also cope with extreme conditions (e.g. high humidity, high temperatures).
The manufacturing plant in Schenkenzell meets the latest standards in terms of environmental technology and energy efficiency. To that end, Duravit has invested in state-of-the-art systems. Focal points are the heating system that makes use of waste wood, a demand-orientated extraction and filter system, and also the paint shop.
The plant’s excellent energy footprint also benefits from a new LED lighting concept with intelligent control. Energy consumption has been reduced by 10%. Additionally, for instance only PEFC-certified woods or paints with the environmental mark “Blue Angel” are used.
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