At DANREC, production runs 24 hours a day for most of the year. Strong demand means that the company’s current production capacity is fully utilised, and during particularly busy periods, it has been difficult to deliver as quickly as usual.
DANREC is therefore expanding its production facilities with Line 4.
“If we are to continue growing, we need more production capacity. We simply cannot push much more through the existing lines,” says CEO Henrik Immerkær Ohm.
At times, an exceptionally high volume of orders has resulted in delivery times of six to eight weeks. DANREC normally aims to deliver within approximately 14 days, and the new line will help bring delivery times back down.
If we are to continue growing, we need more production capacity. We simply cannot push much more through the existing lines. .
– Henrik Immerkær Ohm, CEO
Increased capacity across production
Line 4 will not be dedicated to one particular product. It will be capable of producing the entire range of DAN-Board ground protection mats.
This will allow DANREC to move production between the lines as required and thereby make more efficient use of its total capacity.
“Our customers must continue to be able to rely on receiving their products quickly, on time and in consistently high quality. The new line gives us the additional capacity we need to remain a reliable supplier in the future,” says Henrik.
Quality remains a key priority. DANREC’s overall complaint rate is below 0.5 per cent, and the vast majority of complaints relate to accessories rather than the ground protection mats themselves.
A new product developed in response to customer demand
The investment in Line 4 will do more than enable DANREC to produce additional mats. With the new line, the company is also introducing DAN-Board Flex – a ground protection mat with a textured surface on both sides.
Demand for a double-sided ground protection mat has come primarily from DANREC’s international customers, who account for more than 80 per cent of DAN-Board revenue.
“As we were already investing in additional capacity, we also reviewed our product range and asked ourselves where there were gaps. We identified a clear demand for ground protection mats with a textured surface on both sides,” Henrik explains.
Double-sided ground protection mats are already available on the market, but they are often manufactured using fixed compression moulds. DANREC, by contrast, extrudes the mats in a continuous process before cutting them to the required dimensions.
This makes production less restricted to a small number of standard sizes.
Flexible dimensions for different applications
In principle, DAN-Board Flex can be produced in widths ranging from approximately 50 centimetres to 2.5 metres and lengths ranging from approximately one to four metres. Its thickness can also be varied from approximately 6 to 24 millimetres.
“When producing with a fixed mould, you would typically choose two or three sizes. If you subsequently want different dimensions, you need new moulds, which are expensive to manufacture. Our production method allows us to cut the mats to size and work far more flexibly,” says Henrik.
The ability to vary the dimensions of the mats makes it easier to tailor them to different applications.
One example is work in cemeteries, where the paths between graves can be very narrow. In these settings, a narrow ground protection mat can provide access for smaller machinery while protecting grass, gravel and other surfaces.
Other applications require larger and more robust mats. DANREC has already produced custom dimensions in response to customer requests, including mats measuring 2.5 by 3 metres with a thickness of 22 millimetres.
“Customers may have very different requirements in terms of width, length and thickness. The new production line enables us to accommodate these requirements far more effectively,” says Henrik.
With Line 4, DANREC will gain increased capacity, a broader product range and greater scope to tailor production to customers’ specific requirements.
