Automotive

Growermetal has undergone continuous evolution in order to set itself as a leading supplier of washers and parts for the automotive sector – with its certified productive model, international sales network, and rooted know-how in fastening technologies, enabling it to embrace mobility transformation.

The automotive industry is a rapidly evolving field characterised by dynamic trends and the necessity for stable, reliable supply services. Growermetal has embraced these challenges with an innovative approach, offering comprehensive in-house services, cutting edge research and development, as well as a wide range of washer solutions tailored specifically for the automotive sector.

Since its foundation in 1950, Growermetal has built a strong reputation in the fastener industry by continually enhancing its production capabilities to ensure superior safety and high performance. Over the years, the automotive industry has become a focal point for Growermetal, prompting the company to meet stringent requirements and adapt to new market demands.

For instance, in 2011 Growermetal obtained the IATF 16949 certification, which is specifically for the automotive industry and provides quality management system process requirements. In particular, the standard focuses on customer requirements, defect prevention, improvement and a reduction of variation and waste in the supply chain.

Today, Growermetal’s commitment to quality and innovation is evident in its ability to respond to the evolving needs of the automotive sector. This dedication has allowed the company to establish itself as a trusted supplier of high-quality fastening solutions, earning the confidence of automotive manufacturers worldwide.

Exploring the evolution of mobility

For the fastener industry, the transformation undergone by the mobility and automotive sectors has brought significant new
trends. The transition towards electric vehicles, technology 4.0, and the consequent introduction of more demanding and strict regulations, present unique challenges and opportunities for the fastener sector.

As a consequence, the market of fastening systems is undergoing profound changes too, being called to improve locking performance and safety; introducing lightweight materials with no discount on resistance and durability; as well as designing parts with the integration of smart technologies.

Growermetal has proactively addressed these needs by leveraging its efficiency and technical expertise to develop products that meet the highest standards of quality and reliability.

The centrality of innovation in the company’s strategy is clear from different points of view. On the one hand, Growermetal is working on the integration of smart technologies inside washers – leading to the development of its first smart sensorised washer Grower Detecto^® – and on the creation of products suitable to electric vehicles, such as the metal parts with glued EPDM inserts that can be used as insulation in batteries.

On the other hand, the company is actively investing in new structures for research and development. As a result, Growermetal will soon inaugurate a new building in the area next to its main headquarters, with construction having started in 2023. The GIC – Growermetal Innovation Center will include new areas for sharing ideas and projects, laboratories and classrooms for training, as well as helping support the future development of innovation for automotive, transportation technologies and many other sectors.

Certified quality and comprehensive in-house services

Growermetal’s production process is highly centralised, encompassing various departments that work in unison to maintain a seamless workflow. The headquarters in Calco, Italy, covering a total area of 45,000m² (with 23,500m² of covered space), houses several key departments, including: 

• Tool shop: Growermetal offers mould and tooling design, manufacturing, and maintenance, for producing high-quality components. The tool shop is equipped with advanced machinery and skilled technicians, who ensure that every tool meets stringent quality standards. This capability allows the company to produce custom solutions with high precision, offering a flexible service and adapting it to customers’ requirements.
• Heat treatment: Essential for achieving the desired mechanical properties in fasteners, the heat treatment department utilises advanced furnaces and precise temperature control to ensure that fasteners achieve the required hardness and
  strength characteristics.
• Mechanical zinc plating: Providing exceptional action against corrosion, Growermetal’s mechanical zinc plating is a highly resistant coating certified to the FCA PS.50042 automotive standard. Thanks to the use of original MacDermid® chemicals, and constant monitoring, the company ensures a uniform and durable coating that meets the stringent requirements of automotive manufacturers, with the possibility of supplying the coating on the company’s products, as well as on the products of third parties.
• Zinc flake coating: With a wide range of zinc flake coatings, Growermetal provides quality and aesthetics to the entire production, adding extra protection against corrosion to its washers and parts. During the process no hydrogen is produced, eliminating the risk of embrittlement of the pieces and the exclusive use of original Dörken chemicals completes the offer with different base and topcoats.

Besides these services, Growermetal’s production processes also covers blanking, coining, steel wire rolling, surface cleaning and finishing, as well as sorting and final quality control. Each department communicates directly with the others, ensuring a well defined production flow with minimal interruptions. 

Together with its complete set of services, another one of Growermetal’s strengths lies in its extensive range of fastening solutions for the mobility sector, with the possibility of customisation according to customer’s specific measurements. Available in several different materials and dimensions, the washer range for the automotive industry includes:

• Flat captive washers: These parts are very common in automotive applications, as they suit wider uses. Flat captive washers prevent surface damage and embedment from nuts and bolts, as well as providing a consistent surface for more predictable joints. 
• Ribbed flat washers: Ideal for use with soft-bearing surfaces such as aluminium and plastic, these washers feature radial ribs and serrations to prevent damage during tightening. Ribbed flat washers are particularly useful in applications where a secure grip is required, such as car body, engine, gearbox and other components.
• Conical elastic washers: Designed to prevent loosening in assemblies and accommodate static loads, these washers combine elastic compensation with the elimination of play. They are suitable for applications with low vibration resistance and parts subject to temperature variations.
• Eccentric washers: Commonly used in car and van suspension systems, these washers are essential for ensuring secure connections. The hexagonal hole washer is mounted and blocked on the underhead of the screw, while the counter washer is mounted in the two grooves of the bolt’s threaded part by the OEM during the assembling process of the car.
• Crown lock washers for shafts: These economical and easy to use retainers are used in applications where it is necessary to position and securely retain a bolt or screw until a nut is applied to complete the assembly. Once the nut is applied and tightened, these washers provide a secure hold, resisting loosening and back-off rotation. 
• Corrugated elastic washers: This category includes two different types of products, according to the application and the material. Corrugated elastic washers are suitable for soft materials such as copper, aluminium, and plastic, while corrugated elastic damping washers compensate for the axial play of a component. In general, these washers reduce disassembly risk and compensate for misalignment.
• Cup washers and special geometries: Growermetal is also able to manufacture custom engineered washers that meet specific customer requirements, offering the best locking system for the application. 
• High thickness and precision flat washers: These are special products engineered and manufactured by Growermetal according to customers’ technical specifications and drawing. These washers are mainly used in the automotive industry, replacing turned parts.
• Metal parts with glued EPDM inserts: As the washer and the EPDM (Ethylene Propylene Diene Monomer) part are co-stamped, the elastomer adds a superior resistance to high temperatures, steam, brake fluid and other weather conditions. Thanks to the fact that EPDM is an electrical insulator, these washers can be used in automotive applications where there is exposure to electrical currents or whenever it is necessary to avoid electrical conductivity.

“The company’s ability to control every aspect of the production process is a key factor in its success, enabling it to respond quickly to customer needs and market changes, whilst maintaining high efficiency and consistent quality across its product range,” underlines Paolo Cattaneo, CEO at Growermetal SpA.

Inventory and warehouse management

To create trusted relationships with customers, Growermetal also looks to provide logistical efficiency. That is why when OEM customers ask for timely and comprehensive solutions on a large scale, the company promotes a ‘Just in Time’ approach with an integrated supply service. Starting with its stock of raw materials and finished products, and ending with a distribution network of two important sales branches in North America (Growermetal USA) and Brazil (Growermetal do Mercosul), the company is able to serve automotive manufacturers all over the world.

In particular, Growermetal’s headquarters counts on a fully automatic warehouse with 17 levels of storage and 11,000 storage locations, supported by a management software (WMS – Warehouse Management System) exclusively tailored to meet the company’s requirements.

The warehouse is also equipped with stacker cranes and laser guided vehicles, ensuring that products are stored and handled with maximum accuracy and speed, reducing lead times and improving overall efficiency.

Finally, the new automatic packaging machine enhances this process, offering customisable packaging solutions to meet diverse customer needs. The machine is capable of handling various packaging formats, allowing Growermetal to provide tailored solutions that align with the specific requirements of each customer.

Growermetal participating at IZB 2024

Growermetal’s focus on automotive extends to the participation in important international events, such as the International Suppliers Fair (IZB) 2024, held from 22^nd to 24^th October 2024 in Wolfsburg, Germany, with Growermetal’s team present on stand 6106 in hall 6. 

This prestigious event is a key platform for the automotive supply chain, attracting suppliers and professionals from around the globe. The 2022 edition saw 940 exhibitors from 37 nations and 43,000 world premieres, and the twelfth edition is expected to maintain this trend.

“Covering the entire value chain, IZB will be the occasion to discover Growermetal’s latest innovations and connect with key industry players,” reports Paolo. “Through our participation in events like IZB 2024, and our dedication to R&D, we aim to forge new partnerships and strengthen existing relationships – spreading our commitment to driving innovation and excellence in the automotive industry. With a strong legacy of expertise and a forward thinking approach, we are ready to seize future challenges and opportunities.”