Company portrait: Hasenkopf

Elbphilharmonie, Innenansicht, Fotografie: © Christian Hoehn

The term manu­fac­tory remains ambiva­lent for the Master Council just as well, because it suggests a histor­ical context that no longer applies to most compa­nies. Espe­cially those compa­nies that have a high percentage of manual work but at the same time are highly tech­nical have to live with this concep­tual balancing act, which no longer adequately describes their own perfor­mance.

The Bavarian manu­fac­tory Hasenkopf, based in Mehring, is there­fore delib­er­ately called “Indus­trie-Manu­faktur”. Founded in 1964 as a small supply company with only two employees, Hasenkopf is today known along the entire product chain for its proven crafts­man­ship in supply work and offers first-class prod­ucts made of a wide variety of premium mate­rials as well as tailor-made drawer solu­tions.

Produc­tion process, Hasenkopf, Photo: © Chris­tian Hoehn

With over 200 employees and a produc­tion area of 22,000 square metres, the company manu­fac­tures system solu­tions for trade, commerce and industry throughout Europe. For more than 25 years Hasenkopf has been a pioneer in the processing of solid surface mate­rials such as Corian, Hi-Macs, but also Parapan and GIFAtec. With the newly devel­oped casting tech­nology, as a further tech­nology in solid surface processing, Hasenkopf has once again signif­i­cantly increased the produc­tion effi­ciency for series produc­tion. This enables Indus­trie Manu­faktur to combine crafts­man­ship with indus­trial effi­ciency.

Hamburg, Elbphilharmonie

With the comple­tion of the Elbphil­har­monie, Hasenkopf has completed the largest project in the company’s history to date. Despite the many initial impon­der­ables, the company assessed the chal­lenge very real­is­ti­cally and planned the capac­i­ties accord­ingly. Hasenkopf flex­ibly mastered unfore­see­able prob­lems — without neglecting everyday projects. With state-of-the-art tech­nolo­gies and decades of expe­ri­ence, the “White Skin” was completed after seven years.


Elbphil­har­monie, Photo: © Chris­tian Hoehn

The Hamburg Elbphil­har­monie can proudly be counted among the ten best concert halls world­wide. The deci­sive factor for this is above all the unique, over­whelming acoustics in the “Great Hall”, the heart of the newly built Phil­har­monie. The archi­tects Jacques Herzog and Pierre de Meuron of the renowned firm Herzog & de Meuron, Basel/Switzerland, have worked closely with the world-famous Japanese acousti­cian Yasuhisa Toyota, Nagata Acoustics, to fine-tune the archi­tec­ture for the perfect sound. Through the ideal inter­play of room geom­etry, mate­rials and surface struc­ture, the sound of the music is scat­tered in every corner of the concert hall.

“The unique inte­rior trim, the so-called “white skin” made of the premium mate­rial GIFAtec®, was devel­oped with the help of elab­o­rate 3D calcu­la­tions and tests. Here, no panel is iden­tical and no honey­comb struc­ture repeats itself. GIFAtec® gypsum fibre concrete from KNAUF Inte­gral perfectly meets the require­ments for a concert hall: the mate­rial is extremely solid and non-combustible. In combi­na­tion with the shell-shaped struc­ture, this creates a unique sound. The client repre­sen­ta­tion, ReGe Hamburg, commis­sioned the general contractor HOCHTIEF to imple­ment the gigantic construc­tion project. Peuckert GmbH, based in Mehring, Upper Bavaria, was respon­sible for handling the “White Skin” project. As a supplier specialist with many years of expe­ri­ence in 3D processing, Hasenkopf Indus­trie Manu­faktur processed 10,287 unique pieces for the 6,000 m² wall and ceiling cladding for Peuckert GmbH over a period of seven years.

Complex CAM program­ming and CNC machining 3D surface machining with ultra-modern CNC machining centres has long been one of the core compe­tences of Indus­trie Manu­faktur. Invest­ments amounting to millions for high-tech machines and soft­ware programs were neces­sary. Today Hasenkopf has a modern machine park with 13 CNC machining centres and has acquired compre­hen­sive know-how in handling CAD-CAM systems. The 3D CAD data was converted into machine-capable CNC programs during the work prepa­ra­tion phase. The macros created comprise a total of 352 million lines. Using the defined macros, the glued gypsum fibre boards were processed on both sides. The milling depth of the struc­ture on the front is between 5 mm and 90 mm. More than 1,000 high-quality, diamond-studded milling tools were used for more than 1.5 million linear metres of milling distance.

Perfec­tion down to the smallest detail

In order to achieve a perfect final result, each of the 10,287 compo­nents of the wall cladding, the hall ceiling and the reflector was finished by hand. After the last correc­tions during the grinding of the shell-shaped valleys, all finished unique spec­i­mens were addi­tion­ally painted.

Compre­hen­sive docu­men­ta­tion and quality control

Each element of the “white skin” was numbered and cata­logued in the CAD plan­ning. Since the indi­vidual compo­nents were assem­bled by Peuckert GmbH on site in Hamburg and mounted on the steel substruc­ture, all unique items had to be produced, sorted and pack­aged exactly according to plan. Quality proto­cols ensured that the indi­vidual work steps at Indus­trie Manu­faktur were precisely docu­mented and checked — the number of defec­tive indi­vidual parts was limited to less than 20.