Long-Term Reliability: Assyx DuroBoards in use at
Semmelrock (Wienerberger)
Assyx, headquartered in Andernach, is known as a manufacturer of high-quality production pallets featuring a polyurethane coating from Covestro and a core made of laminated veneer lumber (LVL). This combination ensures exceptional durability and outstanding performance - even under the harsh conditions in concrete block production plants.
An impressive example of the quality and longevity of Assyx pallets is their use at Semmelrock Stein+Design, a subsidiary of Wienerberger. Nine years ago, 9,000 DuroBoards were delivered to Semmelrock in Gnatowice, Poland. The company, recognized as a leading provider of high-quality construction materials and infrastructure solutions in Central and Eastern Europe, offers innovative and aesthetically appealing solutions for private and public spaces.
Long-term reliability
Semmelrock produces concrete products at its Gnatowice facility. The pallets used in these lines measure 1,400 x 1,150 x 50 mm and are subjected to production loads of up to 600 kg.
The 9,000 Assyx pallets have performed exceptionally well under these demanding conditions over the years. Thanks to the robust polyurethane coating and the durable LVL wood core, they have remained in excellent condition.
Refurbishment before reuse
In order to maintain the high-quality standards in Semmelrock facilities and to use the boards for just as long again, the production boards undergo a thorough refurbishment process at the Assyx processing center.
The design of the Assyx DuroBoard ensures that the average 2.75 mm-thick polyurethane layer protects the LVL wood core, which is crucial for vibration transfer, from moisture and other environmental influences. Unlike solid wood variants, the LVL wood core is not in constant contact with external conditions, allowing for significantly longer service life.
The use of LVL wood aims to replicate the benefits of hardwood while eliminating its drawbacks. By using special layered constructions made from spruce, pine, or highly rigid beech, Assyx tailors the properties of the boards to meet customer requirements. The robust adhesive bonds ensure long-lasting quality and even after years of use there is minimal loss in vibration transfer performance.
The physical properties of polyurethane remain stabile throughout the product’s lifetime, enabling repairs even after many years. Customers can either repair their DuroBoards on-site or have them professionally refurbished at the Assyx processing center. Damaged areas are prepared for repair by grinding, milling, and cutting, without reducing the overall thickness, thus preserving the stiffness of the pallets. Cracks and indentations are filled with a specially developed filler, and the wood core is resealed. These processes significantly extend the product’s service life and delay the need for new purchases.
This approach saves customers not only money but also time, as only the damaged pallets need to be repaired. If the entire surface was to be grinded down by several millimeters, a time-intensive rework of the entire batch would be necessary.
The High-Tech Assyx Processing Center
The Assyx processing center, installed in 2019, operates in three shifts and uses state-of-the-art technology for specialized treatments. These advanced processes allow complex tasks to be completed in the shortest possible time. For example, the refurbishment of the Semmelrock pallets can be completed within just a few weeks – a testament to the center’s efficiency and capabilities.
Assyx invested a seven-figure sum in the processing center to establish a new quality standard for the serial refurbishment of pallets. Since its installation, the facility has been operating at full capacity and has become an essential part of the production process. It has also reduced Assyx’s dependence on external suppliers and significantly increased flexibility in meeting individual customer requirements.
To stay ahead in the future, Assyx is currently planning a 2,000,000 EUR expansion of the processing center. This investment will not only increase capacity but also strengthen Assyx’s position as a technological innovation leader in the industry.
A particular highlight of the processing center is its innovative ability to separate polyurethane from wood. This technology represents an important milestone in achieving a fully circular production process and integrating sustainable solutions into manufacturing.
Innovation and Sustainability
With its combination of high-tech expertise, continuous innovation, efficiency, and sustainability, Assyx is setting new standards in the industrial processing and refurbishment of materials.
Assyx is committed to sustainability, combining durable products, resource-efficient materials and energy-efficient processes into an environmentally friendly overall concept. The robust polyurethane-coated pallets with a responsibly sourced wooden core provide maximum stability while reducing the use of synthetic materials. Energy-efficient production, including a 2,000 m² photovoltaic system and the use of 100% green electricity minimizes CO₂ emissions. By collaborating with regional suppliers, Assyx reduces transportation distances, supports local economies and decreases dependence on international supply chains. Additionally, a comprehensive waste management strategy ensures the reduction, recycling, and proper disposal of production waste, further minimizing environmental impact.
