Vorstellung des ersten Counters aus Polycristalit

hergestellt by Teamwork Aura in Sepang,
Kuala Lumpur, Malaysia


Lizenz und Ueberwachung
von Wolfgang Feierbach

Since 1994, it was not possible to win tenders for international projects. We received Request from many airport projects, offered them our best prices, but getting orders where almost impossible. Here at a big project Malaysia Kuala Lumpur international airport we had to change direction and go a much different way. A locale company, owned by some Kuala Lumpur architects became our direct client. I had influenced them, that we can offer maybe a cheaper price, when we can manufacture the counters very close to the project side. The tree architects promoted an Malaysian Factory Manager and fund, to start such factory with my help. I was in this time often in Kuala Lumpur and kept my eyes open. I saw at many places empty industry buildings, where the government had already built hangars, for small and medium industrial firms. 5 km from the airport site at Sepang I saw such a location and I mentioned this to the manager, Rahman Jasman of the new created company with the name Teamwork Aura. Rahman managed to rent three buildings and I was in charge for the planning. One building was for casting Polycrstalit, one building was for finishing and carpentry, and one building was for other projects they had in mind.

This was the Polycristalit mixing and casting building. Most machinery was shipped from my plant in Altenstadt, due to the time frame we had to follow. The first machine on the left is a drum mixer. We shipped all material from Germany in Container to Kuala Lumpur and Sepang. The drums of material contained the right quantity of Filler and the right quantity of resin in a plastic bag above. On this machine the drum was opened, the plastic bag was pierced with a lance and pulled out empty. Than the mixing gear was slowly lowered while turning, to make a consistent mix of Polycristalit without going via a complicated compounding process. When the content of the drum was consistent and all extra components Where mixed. The drum was taken away from this machine. The lid was fastened on the drum and so the drum was attached to a tumbling mixer, the drum was tumbling for 3 hours under vacuum to evacuate the internal air mixed by the filler into the material compound. On the other side of the same building, stabile tables where placed in 100% horizontal position and the molds where placed on that table. Half hour before casting time the hardener was add to the tumbling drum and 20 minutes of tumbling was switched on. The drum was then attached to a drum handling device rolled to the molds and the Polycristalit material was cast into the molds as fast as possible. Within another 20 minutes. The drum had than to be empty and cleaned immetiately.

Several types of drum movers where used. Each drum contained 300 kg mixed Polycristalit, such drums could not been handled by hand. Therefore such drum movers where necessary. This one here was just to move the drums to the drum mixer or for general movements.

This drum mover was used to cast Polycristalit into the molds. It was redesigned by us, to hook in, the drum inclusive the tumbling wheel to be fast in handling. 20 minutes only, was the liquid phase of Polycristalit and casting had to be finish, after this time, at the temperatures in Malaysia. Immediately after casting, the drum and everything in contact of liquid Polycristalit had to been cleaned within minutes, to avoid curing of Polycristalit at anything needed clean after casting,or for next time.

To minimize time, the last amount of Polycristalit was cast, fast into small buckets to empty the drum as fast as possible. All molds where restricted to flat panels only, and the counter for Kuala Lumpur was designed to bolt big side panels to an Electric box base unit. Also this base unit was clued together from ready in size and shape, cast flat panels.

Here a thick stream of Polycristalit flows out of the drum, into several sections of a mold. The mold was easier to move to the side, as the drum mover was.


Casting for fine tuning

Casting for fine tuning

Casting for fine tuning

all molds where sast within 20 minutes.

The smell of Polycristalit attracts the flies so one was watching and chasing away most of the flies.

Renate is using an hairdryer to chase the flies and
to destroy the micro bubbles, wich would not burst
from allone in the short curing time.

The casting drum and all tools contacted to liquid Polycristalit had to be cleaned in the shortest possible time.

The carpenter works on details.



The electro boxes where clued together from individual flat panels with liquid Polycristalit in a Template, made from our pattern maker here in Germany. The electro box was the center Item of a counter, Side panels where attached left and right and a table top and two peace’s of natural granite completed the counter.

Ready made electro boxes where stored in the second building, the carpenters workshop, waiting for delivery to site and beeing istalled.

Series of electro boxes waiting for delivery

The Manager,of the firm, Teamwork Aura.

Rahman Jasman

Rollout, of the first counter made from Polycristalit
in the new factory in Sepang, in 5 km distance to
the airport site of the international airport Kuala Lumpur, Malaysia.


Thank you very much for visiting my Homepage
Best Regards
Wolfgang Feierbach

interesting companies to apply for licensing,
please contact:

Wolfgang Feierbach, FG Design

Industriestr. 6
63674 Altenstadt Hessen Germany
Tel. Büro: ++49 - 6047 - 1452
Tel Privat: ++49 - 6047 - 4003
Fax:++49 - 6047 - 4432
E-mail: Bitte senden Sie Ihre Mails an diese Adresse