Transit Bus Market Services

Wabtec Bespoke Composite Moulding Manufacture Support

Bespoke Composite Moulding Manufacture

Brecknell Willis Composites manufactures high quality composite mouldings ranging from hand held Arc Shields to Train Cabs & 23 Meter Radomes.
 
Resin Systems:

  • Polyester: A general purpose system that can meet Fire specifications from CLASS 3 to 1.
  • Synolite 5001-T-1: For Electrical protection used for many Arc Barriers and Arc shields.
  • Phenolic: Exceptional fire, smoke and toxicity performance.
  • Vinylester: Extremely stable, perfect for tooling and moulds.

 
Reinforcements:

  • Chopped strand Glass Fibre mat
  • Woven Glass & Carbon Fibre Fabrics
  • Foam Core reinforcement

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Calendering

Premium rubber coated fabrics and sheet stock available cured or uncured. Custom compounding, configurations in a range of elastomers and fabrics (some U/L listed). Excellent for use in molded applications as well as gasket and die cutting material

Wabtec Composite Finishing Paint Assembly Servicing

Composite Finishing and Assembly Service

Brecknell Willis Composites boasts an expansive finishing workshop. 
 
Finishing

  • In-house spray paint & bake facilities
  • "Self-coloured", Gelcoat finish mouldings

Assembly
For more complex components, some assembly is required. This may involve drilling holes, adding threaded inserts or bonding other reinforcement onto the composite material.
 

Wabtec Repairs Composite Refurbishment Service

Composite Refurbishment Service

Due to the adaptable nature of composite materials, many components can be repaired after being damaged or worn out. Brecknell Willis Composites offers regular refurbishment and modification services to extend the lifespan of their customer's GRP products.
 
Refurbishment services:

  • Product modification
  • Insert replacement
  • Cosmetic repairs
  • Structural Composite repairs

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Design and Engineering Project Management

Our international success is built on close partnerships and focus on design, engineering and professional project management
 
”More than 30 years of experience and supply of more than 45.000 sanitary systems to the global train industry”.
 
The entire Semvac organisation is driven by an understanding and respect for the present and future needs of our customers.
 
We handle all project phases, from consultancy and discussions in the initial phases through product development, manufacture, supply and after sales service.
 
The requirements from the international railway industry for safety, design and functionality, user friendliness are respected and applied by Semvac for complete cabins and right down to the smallest component.
 
Whatever the complexity of the assignment, our customers benefit significantly from the many years of experience and creativity of our competent employees, producing perfectly tailored solutions in keeping with the requirements of the trains of tomorrow.
 
All products that leave Semvac are thoroughly inspected and tested according to precise and approved standards and procedures, so that we ensure that as a minimum, we adhere to industry standards in order to be able to supply the highest, most consistent quality – every time.
 
Semvac has not finally sold a product before it is implemented and in service to the end-user’s full satisfaction. We take our commitments very seriously throughout the entire lifetime of the product. We provide professional and effective service, via our own highly skilled employees and via our global partners that are all available for rapid and effective assistance.
 
All systems and products are covered by a comprehensive guarantee, wherever they may be located in the world and all of our international partners are very thoroughly trained in providing rapid and effective problem identification and solutions.
 
"All products leaving our factory are carefully tested in our own, advanced testing facilities”

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Elastomer Bonding & Overmolding

Rubber-to-fabric, rubber-to-metal and rubber-to-phenolic / thermoset. Specially formulated adhesive systems strong enough to provide consistent bonds that withstand flexing and chemical attack found in harsh environments

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Mandrel Building

Supported and unsupported elements from 1" to 30' long in a range of diameters. Autoclave curing (30" high x 52' long or 78" high x 53.5' long). All rubber, fabric-reinforced rubber and metal-reinforced rubber

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Molding

Compression, injection and transfer molding. Rubber, bonded rubber / overmolding, phenolic and thermoset materials with custom formulations available. Small to large part sizes; low to high volume production capabilities.

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Orcomatic Molding

Proprietary molding process. Cost effective solution for continuous, high-volume production of small components with single or multi-cavity setups.

Wabtec Patternmaking  service layup infusion bagging tooling

Patternmaking Facilities and Expertise

Brecknell Willis Composites offers a comprehensive in-house patternmaking service. This allows BWC to collaborate with customers to produce bespoke tooling before manufacture commences, ensuring the pruduct supplied meets their exact requirements.
 
Manufacturing processes:

  • Hand layup
  • Vacuum infusion
  • Vacuum bagging
  • Cold press tooling

Quality & Services

Quality & Services
We provide extensive services, which fully comply with customer requirements. 100 years of experience and our technical expertise in development, production, maintenanceafter sales service/spare parts and quality practice go into these services. We take care of our customers’ and clients’ needs, apply a holistic and solution-oriented thought process, act flexibly and help quickly at home and abroad.
As a manufacturer, we supply you with original spare parts “Made in Germany” during the entire application period of our products.
 
Development
Constructive know-how for customised solutions
The main focus of our constructive services is in compiling solutions made to measure for challenging assignments together with our customers. From the idea of a producible component as a one of a kind or serial product. Numerous innovations and records attest to the quality of our constructive work.
Many of our teams of engineers have international experience and have been working together in well-established project teams for many years. Professional equipment and tools go without saying. Efficient processes throughout all phases also ensure the economic success of the project for our clients.
Creative design

  • Engineering work for international sales orders
  • Development of serial products and special-purpose solutions 
  • Upgrading and optimisation of existing customer systems
  • Modification of our own standard series and technologies
  • Development of innovative technologies/system solutions
  • Constructive work in international joint projects

 
Service and Maintenance
Ensuring ongoing availability
Routine and all-round maintenance prevents uncontrollable downtimes. Upon request, we put our own as well as third party components and products through their paces.
We strive to make mobile equipment available at all times in everyday industrial life. For this purpose, we have competent and skilled service technicians at our disposal with standardised tools and equipment. We would be more than happy to compile an individual maintenance proposal for you.
 
Acting instead of reacting

  • Routine, predictable maintenance intervals
  • Application of original spare parts
  • Ensuring ongoing availability
  • Direct cost control

 
After sales service/Spare parts
High class German workmanship for international markets
We cover the entire production range of our energy and data transfer systems in a 15,000 sqm roofed production area. We manufacture, assemble and carry out a thorough inspection of technical core components as well as most of the products before delivery. This makes it possible for us to quickly manufacture high quality spare parts for your requirements and to provide our customers with them just as quickly.
Extraordinary expertise in development and production enables us to advise each customer individually and to support each customer effectively in any situation. Lean structures, dedicated employees and state-of-the-art machinery ensure punctual delivery.
 
High quality work from A to Z

  • short reaction times according to customer requests
  • efficient product development based on proven and tested technologies/model ranges
  • production according to international standards and directives
  • internal assembly, quality control and testing
  • quick delivery, even for large contract volumes
  • extensive customised services

 
Quality Management
Highest quality for satisfied customers
The quality of our services and products is aimed at the complete fulfilment of our customers’ wishes, needs and expectations. In the process, the benchmark for the assessment of our quality is first and foremost set by you - our customer.
Internal quality management ensures compliance with international standards and directives. The implementation of the QM system is carried out according to standardised methods and with the help of flexible tools for the modelling and documentation of all production and business processes (DIN EN ISO 9001:2008).
 
Certificates and Approvals

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Spare Parts and Aftersales

On time supply of original spare parts and qualified after sales service keep the trains on the track
 
Modern and effective railway operators expect and require efficiency and reliability of the sanitary systems. No train shall be out of service unnecessarily, but must remain on the tracks, practically 365 days a year. Semvac understands this to perfection.
 
All operators all over the world expect a fast and efficient service in the event of an unexpected incident.
 
Therefore Semvac offers:

  • Continued supply of OEM spare parts throughout the lifetime of the product.
  • Fast and effective assistance and response via our network of global partners.
  • Continuous specialised training and ongoing product updates of all of our partners, including train manufacturers, operators and service centres.
  • Preventive and systematic maintenance of all products.
  • Support and service “24/7” – no problem is too small or large – we help to get trains back on the tracks.