Lumag is not only the brake pads! We also offer accessories.

In our offer, there are not only high-quality brake pads. Our company produces brake pads fitting kits, as well. They are made at our another location at Osiedle Cechowe in Budzyń.

After typing “Lumag” in the satnav, probably the first destination point will be the registered office of the company at Rogozińska street in Budzyń. It is correct but not the only address of the brake pads manufacturer from Greater Poland region. Its other location is Osiedle Cechowe where brake pad accessories are manufactured.

At our second location, which has undergone a metamorphosis lately, takes place the production of steel components for brake pads – says Łukasz Żak, Marketing Manager at Lumag. I mean components such as backing plates, shims as well as other mounting accessories – he adds.

Lumag factory at Osiedle Cechowe has a functional space of the floor area of 8 000 square meters. Apart from the production department, it also houses engineers’ offices, the tool shop and the construction department.

Currently, for the production, available are two Finetool lines and high speed stamping press Bruderer with packing unit. – says Grzegorz Żak, Head of production metal parts of Lumag

This sort of technical infrastructure enables the self-sufficient production of the accessories for brake pads. A press with the peripheral equipment allows us to trim plates of fineblanking quality and larger mounting accessories. In turn, the Bruderer fast stamping line is burdened with the production of shims and piston clips. These components are subsequently sent to the factory at Rogozińska street, where they become a part of the brake pads.

So-called shims deserve special attention.

They are anti-squeal anti vibration, harshness rubber metal sheets, invisible at the first glance, which with no doubt are one of the key components of the brake pads. Most of all, they provide vibration dampening and noise reduction. Mounted on the brake pads, they also provide thermal insulation, protecting the brake fluid and the callipers from overheating. During the everyday drive, shims reduce generated noise as well as improve the efficiency of the braking process – explains Łukasz Żak.

At Lumag, we consistently expand our portfolio of the manufactured products. Our strategic decision on investment in the so-called “stamping operation” first and foremost allowed the company to secure our customers’ interests against problems with the supply of the aforementioned components. Consequently, it diversified our core business, as all of the steel components manufactured by Lumag are offered to other producers of friction materials.

Production automation is also an important matter. Because the processes are set up in uninterrupted process lines, one operator can handle two lines that are under the control of the SPC system.

This offer was created to fulfil not only our needs but also the needs of other producers of friction materials we co-operate with. The fact that we strive to fully utilise our production capacity so that the cost per product is as low as possible is an additional incentive to work with us – says Łukasz Żak.

Can brake pads be eco-friendly? Lumag is conducting tests

A new acquisition of the Lumag company located in Budzyń intrigues passers-by. The measuring devices installed on the car body are an eye-catcher. The inconspicuous apparatus will prove to be a leap in trying to understand the needs of green energy car users.

Electric cars are an increasingly common view on European roads. According to the European Environment Agency, almost 550,000 of them were registered in 2019 in the European Union countries. On the one hand, it is an invaluable relief for the environment, but on the other hand, it is a big challenge for brake pad manufacturers who have to adapt their production to market requirements. In order to better understand the needs of users of green energy cars, the Lumag company, the owner of the Breck brand, purchased VW ID.4, which will test new solutions useful in the production of friction materials.

The car will be used to test the friction materials under development for electric vehicles. The main development of friction materials will be carried out on an inertia brake test rig, the so-called dynamometer”, says EngD Tomasz Orłowski, the head of the Lumag’s Research and Development Department. “However, the tests on the vehicle are the final and most important confirmation of meeting the previously assumed requirements”, he adds.

A lot could be said about the differences between electric and internal combustion cars. While the external appearance of these cars remains almost unchanged, they differ in design solutions and technologies that are not visible from the outside. One of many examples of such differences turns out to be the braking system and the braking itself.

Electric vehicles recover part of their kinetic energy during braking, converting it into electrical energy. The electric motor then acts like a generator, charging the batteries with the energy generated”, points out the head of the Lumag Research and Development Department.

At first glance, it might seem that such a solution generates savings due to the almost negligible operation of the brake system. This would mean that the economy that goes hand-in-hand with the use of electric cars should be perceived much more broadly. Unfortunately, reality mercilessly brings all those who think this way down to earth.

In general, the main problem of braking systems is their susceptibility to corrosion; this especially applies to discs and, to a lesser extent, brake pads. Braking systems should be used frequently to remove thin layers of corrosion products. If they are not – and this is a common situation in electric cars, which mainly reduce speed thanks to regeneration – the discs can rust and the next braking with the use of the braking system will be uncomfortable. Very infrequent use of the brake for long periods of time can even result in pitting on the surface of the brake disc, which will cause the steering wheel to vibrate”, says EngD Tomasz Orłowski.

A partial solution to this problem may be the use of drum brakes, which are less susceptible to corrosion due to their built-in design. This is the factory-fitted solution on the rear axle of VW ID.4, an electric car purchased by Lumag for road tests, which also draws attention with its unusual appearance. This appearance is about the measuring instruments placed inside and on the body of the car. It is the LINK VMAX 4000 system that consists of a computer with appropriate software and sensors that measure, among other things, squeaks and vibrations of the brake caliper.

The universal nature of the system means that it can be successfully used for a wide variety of tests, carried out in extremely different road and weather conditions”, says Mr Orłowski.“As a result, the specialists on the research team can analyse parameters such as speed, disc and pad temperature, pressure in the brake system, caliper vibration, the intensity and frequency of the sound coming from the brakes, and the stroke and force of the brake pedal. This makes it possible to verify aspects such as braking efficiency, pad work comfort and vibration levels during braking.

The measurements carried out are expected to provide the Lumag specialists with the necessary data to develop friction materials for electric vehicles. The manufacturer aims for such materials to have low dusting, high corrosion resistance and high braking efficiency when the braking system is irregularly used. In the latest phase of research development, the manufacturer intends to expand its brake pad portfolio with friction material products tailored to the needs of users of the most popular electric vehicles.

Moreover, the new electric car in Lumag’s fleet is one of the components that make the company’s environmental strategy, which it has been following for several years, a reality. Recovering rainwater, segregating waste, reducing the amount of plastic foil used, and recycling production residues are just some of the actions taken so far by the Wielkopolska-based manufacturer of friction materials to care for the environment. The company’s buildings also now feature an impressive photovoltaic farm, as well as a charging station for electric vehicles located in the company’s parking lot, which reflects a specific concern for the environment.

Lumag goes green!

Both Lumag sites had a total of 4161 PV(Photo Voltaic) solar panels installed over several months. It is certain now, Lumag is coming to the green side of power!

Violent weather phenomena, the global air temperature rise, and accelerating climate change. These are the unfortunate consequences of operating traditional energy sources, among others. Lumag wants to join the fight for the environment and that is why Lumag is coming to the green side of power by investing in PV power plants.

During the last few months, a CAPEX investment was set aside to build a PV farm, which now comprises 4161 PV panels installed at the two sites belonging to the company. The production building in Rogozińska Street in Budzyń had a PV installation built with 4000 panels! The installed power is 1.24 megawatts. This configuration can generate 1,100,000 kilowatt-hours per year. The remaining 161 PV panels were installed on the corporate headquarters building in the housing project of Osiedle Cechowe. The other PV plant can generate approximately 50,000 kWh of green energy a year.

More importantly, the current PV installation is not where Lumag will stop its green power CAPEX projects. More PV panels will be deployed soon on a green-field site owned by the company. The finished PV plant will have 10,700 PV panels to generate 3,890 MWh a year with a total power of 3.89 MWp. These projects are undoubtedly beneficial to the environment. The energy volume purchased from the grid will be largely reduced. A negative correlation between electricity prices and the cost of finished product manufacture is expected within a long-term horizon.