Gerlach

What Gerlach does

Gerlach Maschinenbau GmbH is a privately held German industrial machinery company founded in 1979 and headquartered in Nettetal near Düsseldorf. The company designs, manufactures, and services continuous vulcanization plants for natural and synthetic rubber as well as silicone profiles, and self-describes as the worldwide technology leader in continuous hot air vulcanization. Its core technology combines hot-air shock channels with supplementary microwave (SHF and UHF modules) and infrared energy sources, arranged in a modular plant architecture (shock channels, microwave channels, cooling channels, extruders, pre-shock equipment, exhaust air purification) that is configured to customer-specific product and throughput requirements. The product portfolio includes the Hot-Air Shock Channel HLK 111 (capable of shock temperatures up to 550°C), microwave modules such as SHF 145, SHF 147, UHF-Module 201, and UHF-Box 205, cooling channels K 176/K 179, extruders from D 35 L/D 15 to D 120 L/D 20, and proprietary expert software (HeatStraD Heating Strategy Developer, GXPS Gerlach Expert System).

Gerlach generates revenue primarily through one-off hardware sales of custom-engineered vulcanization plants and individual machines, supplemented by a recurring spare parts business, preventive maintenance and remote service contracts (including real-time video/audio support), commissioning and operator training, and professional services in R&D, consulting, and process planning. Pricing is quote-based and not publicly disclosed, with systems sold under multi-year contracts adapted to individual customer specifications. The company serves enterprise industrial customers across five primary verticals: automotive (the lead segment, with high-speed profile extrusion for sealing profiles), facade construction, water and wastewater treatment, hose production, and general industrial rubber processing. Distribution is direct via wholly-owned regional offices in Germany (headquarters and main production), the USA (Miami, serving USA/Canada/Mexico), Spain (Madrid), Japan (Tokyo), Thailand (Bangkok), and China (Beijing), supported by a worldwide customer service network. The company operates a vertically integrated, ISO 9001:2015-certified production facility and runs a separate Gerlach Cable Division for cable machinery, indicating diversification beyond its core rubber/silicone profile vulcanization business.

Name

Gerlach

Legal name

Gerlach Maschinenbau GmbH

Website

https://gerlachinc.com

Company type

Private

Founded year

1979

Operating status

Operating

Headcount range

1–10 employees

Short description

Gerlach Maschinenbau GmbH is a German industrial machinery OEM and self-described worldwide technology leader in continuous hot air vulcanization plants for rubber and silicone profiles, serving enterprise customers in automotive, facade, water/wastewater, hose, and general industrial sectors via custom-engineered modular systems and global direct sales.

Ownership category

akta.pro rank

Product category

Industrial Vulcanization Machinery

NAICS

Other General Purpose Machinery Manufacturing (3339), Other Rubber Product Manufacturing (32629), Rubber Product Manufacturing (3262)

SIC

Gaskets, Packg & Sealg Devices & Rubber & Plastics Hose (3050), Industrial & Commercial Fans & Blowers & Air Purifing Equip (3564)

akta.pro primary industry

Molded & Extruded Industrial Rubber Parts (Custom Components) (IMANALAG)

akta.pro secondary industry

Industrial Hoses & Tubing (Rubber/Elastomer) (IMANALAA)

Keywords

• Continuous hot air vulcanization
• Rubber extrusion machinery
• Microwave vulcanization systems
• Industrial vulcanization plants
• Silicone profile manufacturing

Headquarters

HQ city

Kent

HQ country

United States

HQ region

North America

Offices6 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Technology or R&D, Supply Chain, Marketing or Sales, Infrastructure

Revenue model

1. Industrial Machinery Sales: Sale of continuous vulcanization plants and individual machines including hot-air channels, microwave channels, cooling channels, extruders, and supplementary equipment. Custom-built systems tailored to customer specifications with long service life.
2. Spare Parts Supply: High spare parts availability with controlled and certified quality, supporting the installed base of machines worldwide
3. Service & Preventive Maintenance: Full-service concepts including preventive maintenance, remote maintenance, real-time video and audio support (GSS), operator training, and worldwide customer service operations
4. Research & Development Services: Product development adapted to customer requirements, including extrusion and vulcanization trials with customer compounds, off-line material tests, and engineering simulations
5. Consulting & Planning: Planning services for complete vulcanization lines, consulting on technology selection and process optimization
6. Plant Commissioning & Assembly: Complete in-house machine commissioning with customers, assembly services, and installation support

Pricing tiers

Go-to-market motion1 record

Distribution channels3 records

Marketing channels5 records

Core offering

Gerlach Maschinenbau GmbH designs, manufactures, and commissions custom-engineered continuous hot air vulcanization plants and modular machinery systems for the production of elastic rubber and silicone profiles. The company supplies complete extrusion and vulcanization production lines—integrating hot-air channels, microwave channels, cooling channels, extruders, pre-shock equipment, and exhaust air purification—tailored to individual customer specifications for automotive, facade construction, water/wastewater, and hose manufacturing industries. It also provides spare parts, preventive maintenance, remote support, R&D trials, and consulting services.

Product overview

Gerlach Maschinenbau GmbH is a worldwide technology leader in continuous hot air vulcanization systems for rubber and silicone profiles. The company offers a modular overall system architecture that combines multiple specialized modules: hot-air shock channels (HLK 111), microwave channels (SHF 145, SHF 147, UHF-Module 201, UHF-Box 205), hot air channels (GM 500, HLK 106/114, HLK 110 PCT), cooling channels (K 176, K 179), extruders (D 35 to D 120), pre-shock equipment (P 158, V 116, V 117, V 119), exhaust air purification systems (Electrostatic Precipitator 450, Stand-Alone PCT), and supplementary equipment (Heat Tower HT 420, Caterpillar BA 400/501, RollaClean, Flocking machines, Hot Air Module 203). Expert software tools include HeatStraD (Heating Strategy Developer) and GXPS (Gerlach Expert System). The modular design allows customers to configure complete production lines combining different energy sources (hot air, microwave, infrared) tailored to their specific product requirements in automotive, facade construction, water/wastewater, hose production, and other industries.

Differentiator

Problem solved

Functional benefit

Brands

• Gerlach Cable Division: Specialized division for cable machine manufacturing and solutions, operating from cable.gerlach-machinery.com

Products and services

• Modular Overall System A modular plant construction system that allows customers to configure complete continuous vulcanization lines by combining standardized modules including hot-air channels, microwave channels, cooling channels, extruders, and supplementary equipment, tailored to specific product requirements.
• Hot-air Shock Channel Type HLK 111 Compact and flexible hot-air shock channel using special materials, capable of generating shock temperatures up to 550°C with accelerated turbulent hot air for rapid heat transfer in rubber profile vulcanization.
• SHF 145 Microwave Channel Microwave channel system for efficient vulcanization of rubber profiles using Super High Frequency (SHF) microwave energy.
• SHF 147 Shock Channel High-performance shock channel with integrated exhaust air purification (PCT) and recirculation system, designed for high production speeds predominantly in automotive profile extrusion with 3m modular zones.
• UHF-Module 201 UHF (Ultra High Frequency) microwave module for hot-air vulcanization, representing an advanced microwave technology platform designed for retrofitting existing installations and offering outstanding performance and efficiency.
• UHF-Box 205 UHF microwave unit delivering a new level of flexibility in hot-air vulcanization, part of the 'Guided Wave' DUO product line.
• Hot Air Channel HLK 106 / HLK 114 Hot air channel variants designed for specific vulcanization applications within the modular Gerlach system.
• Hot Air Channel HLK 110 (PCT) / HLK 109 Hot air channels with integrated PCT (Post-Curing Treatment) capability for enhanced vulcanization processing.
• Hot Air Channel GM 500 Hot air channel system for continuous vulcanization of rubber profiles, part of the modular hot-air channel product line.
• Cooling Channel Type K 176 Cooling channel designed for temperature control and cooling of extruded profiles during the vulcanization process.
• Cooling Channel Type K 179 Cooling channel with specially designed surge nozzles that maintain cooling function in polluted or calcareous water, featuring blow-off stations and heat exchangers.
• D 35 L/D 15 – D 120 L/D 20 Extruder Extruder machines in various size configurations (L/D ratios from 15 to 20) for rubber profile production, forming the upstream feed component of vulcanization lines.
• Pre-shock Type P 158 Pre-shock equipment using special short-wave infrared radiators arranged in four planes for 360° pre-crosslinking, with 0-100% power modulation, producing excellent profile surfaces and early dimensional stability.
• Pre-shock Type V 116 – Infra-red PreShock Infrared pre-shock equipment for rubber profile vulcanization preparation.
• Pre-shock Type V 117 – Infrared Dark Radiator Pre-shock equipment using infrared dark radiator technology for vulcanization preparation.
• Flow Burner Pre-shock Type V 119 Flow burner pre-shock equipment for thermal preparation of rubber profiles before vulcanization.
• Electrostatic Precipitator 450 Exhaust air purification system using electrostatic precipitation technology for environmental compliance in vulcanization operations.
• Stand-Alone PCT (Post-Curing Treatment) Standalone post-curing treatment system for exhaust air purification and additional thermal processing.
• Stand-Alone Microwave Module Independent microwave module that can be integrated into existing production lines to add microwave vulcanization capability.
• HeatStraD – Heating Strategy Developer Expert system software for developing and optimizing heating strategies in vulcanization processes.
• GXPS – Gerlach Expert System Proprietary expert system providing knowledge-based assistance for machine operation and process optimization in vulcanization plants.
• Heat Tower HT 420 Supplementary heating equipment providing additional thermal processing capability for vulcanization systems.
• OCTOtherm BK 400 Supplementary equipment for thermal processing in the vulcanization line.
• Caterpillar BA 400 Belt extractor for continuous withdrawal of rubber profiles (with and without steel reinforcement), hoses, or smaller plastic profiles, designed for flexible production processes.
• RollaClean Cleaning system for profile processing equipment.
• Caterpillar BA 501 Profile removal and transport equipment for the vulcanization line.
• Flocking Machines Equipment for applying flock coating to rubber profiles.
• Hot Air Module 203 Hot air module for integration into existing vulcanization lines to add hot air processing capability.
• Series GWM 300 Chamsic Cable Machine Cable manufacturing machine series from the Gerlach Cable Division for specialized cable production.
• PTFE Hex 330 PTFE hexagonal cable product from the Gerlach Cable Division for specialized cable applications.
• Service & Preventive Maintenance Full-service concept including preventive maintenance, remote maintenance, real-time video and audio support (GSS), operator training, and worldwide customer service operations for the installed base of Gerlach vulcanization plants.
• Spare Parts Supply Supply of high-availability spare parts with controlled and certified quality to support the installed base of Gerlach machines worldwide.
• Research & Development Services Product development adapted to customer requirements, including extrusion and vulcanization trials with customer compounds, off-line material tests, and engineering simulations.
• Consulting & Planning Planning services for complete vulcanization lines, consulting on technology selection and process optimization for industrial rubber and silicone processing.

Quantifiable outcome

• Shock temperatures up to 550°C achievable with hot-air shock channel type 111 using special materials
• +2 more outcomes

Segments5 records

Ideal customer profiles1 record

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature8 records

Scale indicators5 records

Recent moves5 records

Expansion highlights5 records

Emerging players

• Maplan GmbH: Austrian manufacturer of rubber injection molding machines and related processing equipment. While Maplan's primary focus is rubber injection molding rather than continuous vulcanization, it serves the same rubber processing machinery customer base with custom-engineered production solutions for industrial rubber component manufacturers.
• Reliable Rubber & Plastic Machinery: US-based manufacturer of rubber and plastics processing machinery including hydraulic presses, mixers, and extrusion equipment. While smaller in scope than Gerlach, Reliable serves North American rubber processors with comparable custom-engineered production equipment for similar end-markets.
• Everplast Machinery: Taiwan-based manufacturer of plastic and rubber extrusion equipment including profile extrusion lines. Everplast competes with Gerlach in Asia Pacific markets with comparable continuous extrusion and vulcanization systems for rubber and silicone profile production at varying price points.

Broad incumbents

• Siemens Industry (Process Industries): Major industrial automation and machinery supplier whose drive systems, automation, and control cabinet components integrate into continuous vulcanization lines like those Gerlach builds. While not a direct competitor for vulcanization-specific equipment, Siemens supplies enabling technologies for similar industrial process lines.
• Davis-Standard: US-headquartered global supplier of extrusion and converting machinery, including systems for rubber and silicone processing. Davis-Standard serves similar industrial customer segments with broader product portfolio spanning multiple extrusion technologies and end-markets overlapping with Gerlach's rubber profile production systems.
• KraussMaffei: German manufacturer of industrial machinery for plastics and rubber processing, including extrusion and reaction process machinery. While much larger and broader in scope, KraussMaffei overlaps with Gerlach in rubber extrusion and offers comparable custom-engineered production line solutions to industrial customers.

Direct peers

• Berstorff: German manufacturer of rubber and plastics processing machinery, including extruders, calenders, and continuous vulcanization equipment. Berstorff (now part of the KraussMaffei group) is a direct competitor in continuous vulcanization lines for rubber products serving similar automotive and industrial applications.
• Troester GmbH & Co. KG: German-headquartered manufacturer of specialized machinery for rubber processing, including continuous vulcanization lines, extruders, and calendering equipment. Troester is the most direct competitor to Gerlach in continuous vulcanization plants for rubber profiles, serving the same automotive and industrial customer base worldwide.
• VMI Group: Dutch-based manufacturer of tire building equipment and rubber processing machinery, including extruders and vulcanization-related systems. VMI serves global tire and rubber product manufacturers with custom-engineered production lines comparable to Gerlach's offering for non-tire rubber profile applications.

Regional players

• Italprogetti: Italy-based manufacturer of extrusion and vulcanization equipment for rubber and plastics, serving European rubber profile manufacturers with comparable continuous production line systems. Italprogetti competes with Gerlach primarily in the European automotive sealing profile segment.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat6 records

Key risks6 records

Key highlights6 records

Customer concentration

• LinkedInlinkedin.com/company/gerlach-engineering

Compliance2 records

Revenue estimate

Valuation estimate

Number of profiles

Subsidiaries5 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Gerlach