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Precision in all things
Ilgen Vida
Silivri, Istanbul
By the very nature of the processes involved even the best fastener manufacturing environment
can seldom be described as aesthetic. To every rule, though, there is an exception and Ilgen Vida is
precisely that.
Meet with Tülay Ilgen and no question lingers over the source of a Waterbury Farrell producing flange headed screws.
passion for order and precision that pervades this business. In his office There are many small, but important, indicators of Ilgen’s almost
drawer after drawer is filled with examples of the precision screws Ilgen obsessive attention to detail. The most visible are red painted and
manufactures, primarily for the electronics sector, but also for furniture numbered scrap bins at the end of every machine row – collected daily
and, indirectly, automotive applications. Some, almost gleefully, are they are weighed and recorded as a key indicator of efficiency.
selected for consideration and approval, examples of cold forming taken The production office shares space with a carefully resourced laboratory.
to the verge of art form. Process control entails approval of initial samples before the machine
Ilgen has been manufacturing since 1976, moving into its current runs and testing hourly thereafter. Samples from each production batch
2,600 square metre plant six years ago, where it employs 25 people. are retained for five years. Licensed punches are imported and tooling
Annual production is 700 million pieces working eight-hour days. Around stocks are both extensive
1,650 different standard screws and parts range from 2mm to 10mm and in-depth – Ilgen
in diameter: machine thread, trilobular, self tapping; in steel, stainless, carries out its own tooling
brass, copper, aluminium; with cross, slot, TORX® recesses. Ilgen also maintenance.
produces rivets and semi-tubular parts. “Not all fastener
A new four-die JF former provides a 10mm diameter by 80mm cut companies operate to
off capability for more complex parts. Most machinery on the spotless the same standard,” says
production floor, though, has been in service for a lot longer – although Tülay Ilgen. Not a trace
its condition belies that fact. In its history Ilgen has built 50 machines of of irony tinges what can
its own, several still in service, in addition to meticulously refurbishing only be described as a
many acquisitions – one of the most recent a fully reconditioned masterly understatement.
Big on galvanised
MITASBOLT
Ankara
The MITAS Group is a major international supplier and contractor to the energy transmission tower,
street lighting, steel construction, hot dip galvanising and structural pole markets. Originally state-
owned it was established in 1955 and privatised in 1989. Its 150,000 square metre main site in Ankara
processes 120,000 tonnes of steel each year and has an annual galvanising capacity of 250,000 tonnes.
The MITASBOLT division, to no great surprise, its type in Turkey. A subcontractor manually assembles
specialises in galvanised structural fasteners. It operates nut, washer and bolt sets onsite. Final packing is carried
three Nedschroef boltmakers, even with full sound out on a semi automatic line with 500Kg per hour
enclosures seemingly dwarfed in one of the site’s capacity.
massive ‘sheds’. A BV6 gives MITAS the capability Surrounded by a massive site bustling with large-
of cold forging up to M24 x 205mm long bolts. It scale steel processing and truck movements this
is a flanked by a NB415 and NB416. A sprawling is never going to be the most attractive fastener
mechanical workshop produces a variety of studs, fully manufacturing operation. That should not, though, belie
threaded rod, U and V bolts, and anchor bolts as well MITAS’ commitment to quality. The group is a TS16949
as housing CNC lathes for complex parts, including certified supplier to Renault, galvanising engine cradles
tooling for the cold forgers. for several models. MITAS’ physical laboratory, a haven
Three continuous atmosphere controlled lines, of cleanliness and quiet, is nothing short of impressive.
one electric and two natural gas, provide a current A clean room houses a recently acquired Spectrolab
heat treatment capacity of 1,500 tonnes per hour. spark gas spectrometer for material testing. Alongside
MITASBOLT plans to invest in a new 62 metre long a tensile tester is a special cold temperature (operating
Jianan line to replace the current electrical one and to minus 80˚C) destructive tester. MITAS also uses a
increase capacity. Fastener galvanising is carried out on DEA robotic coordinate measurement machine for
a PLC controlled hot dip and spin line – the only plant of dimensional testing on critical parts and tooling.
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