DREEFS GmbH Schaltgeräte und Systeme, a long-standing German manufacturer of electromechanical switches, has enhanced its production efficiency by integrating advanced material-leveling technology. The company, part of the Everel Group since 1996, specializes in high-volume contact production for industries ranging from automotive to household appliances.
High-Volume Production with Precision
With 23 employees and €9 million in annual revenue, DREEFS produces approximately 500 million contacts per year. Its key products include welded silver contacts for switches used in appliances, automotive systems, and medical devices. The company relies on nine high-speed stamping presses from brands like BRUDERER and HAULICK ROOS, operating up to 1,500 strokes per minute in three shifts.
Each machine is monitored by advanced SPC (statistical process control) systems, ensuring consistent output of 150 to 6,400 parts per minute. This efficiency allows DREEFS to maintain competitive pricing for major clients, including Volkswagen, Miele, and Electrolux, across Europe, the U.S., and Mexico.
Material Innovation Cuts Costs
To reduce expenses, DREEFS shifted from half-hard brass to unalloyed steel (DC01) for substrate materials—a move that required precise leveling to ensure proper silver contact welding. The company adopted a KOHLER CPL 120 precision leveling machine, integrated with a Leicht PWL-150 horizontal decoiler, to streamline material handling.
“The KOHLER leveler simplified coil threading, reduced waste, and improved weld quality,” said Harald Müller, Managing Director of DREEFS. “Switching to steel saved us 90% in material costs, but without this technology, it wouldn’t have been possible.”
Proven Reliability
DREEFS has trusted KOHLER levelers since 1979 and continues to rely on Leicht for material management. The compact design of the new system saves space while boosting productivity.
“Combining the decoiler and leveler was the perfect solution,” Müller added. “It makes our entire process faster and more cost-effective.”
Conclusion
By investing in precision leveling technology, DREEFS has optimized its high-speed production while significantly cutting material costs. The upgrade reinforces its position as a leading supplier of electromechanical components for global industries.
