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Production facilities

Halcor Manufacturing Plants Overview

Halcor, a distinguished leader in the metals industry, leverages its rich heritage of over 85 years with cutting-edge manufacturing techniques to comprehensively address a broad spectrum of market demands.

Strategically positioned in Europe, our operations underscore our commitment to quality, sustainability, and technological advancement. Showcasing achievements in metal manufacturing, Halcor offers a comprehensive suite of products—from copper tubes to insulation materials—exemplifying unparalleled potential. Discover our vision and explore the key features of our four distinct manufacturing plants for innovative products and applications.

At Halcor, we pride ourselves on being more than a producer; we are a partner in progress.

Halcor copper & alloys extrusion division of elvalhalcor Aerial

Copper Tubes Plant

One of ElvalHalcor’s key competitive advantages is the Copper Tubes Plant of Halcor, the central production facility of the Copper Tubes Division of ElvalHalcor S.A., located in Oinofyta. It is one of the largest production facilities in Europe. The production range includes a large variety of copper tubes, such as internally grooved tubes, insulated tubes, coated tubes, straight lengths, and coils, available in hard, semi-hard, or soft conditions. These are utilized in applications including refrigeration, air conditioning, and heat pump (RACHP) systems that lower F-gas emissions, water supply, heating, ventilation, air conditioning, and refrigeration, as well as renewable energy sources, among others. Our Copper Tube Production Plant boasts an annual production capacity of 85,000 tons. The plant operates under the strictest health and safety standards, emphasizing the continuous improvement of working conditions through the active participation and contribution of all employees. Aligned with the company’s Digital Transformation initiatives, and with objectives such as optimal resource utilization, quality and productivity enhancement, improved flexibility and rapid response to customer demand, and better decision-making support, the copper tube production plant is already utilizing modern systems such as Manufacturing Execution Systems (MES), Advanced Planning & Scheduling Systems (APS), and traceability technologies. Striving for excellence across all operational levels, the copper tube production plant has implemented a comprehensive Operational Excellence Program dedicated to developing a high-performance organization through ongoing skills and capability enhancement. This approach is grounded in a transformative work culture built on key principles such as servant leadership, zero losses, standardization, and active employee involvement. It aims to achieve long-term, sustainable results through the systematic use of tools that strengthen daily operational management.

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Halcor copper & alloys extrusion division of elvalhalcor Foundry aerial photo

Foundry

Halcor’s foundry plant supplies the Copper Tubes and Brass Bars and Tubes extrusion plants with semifinished products. By maintaining its own foundry, Halcor ensures operational independence, enhancing both efficiency and quality control in its manufacturing operations. HALCOR’s foundry consists of five casting lines and specializes in manufacturing billets of copper and brass alloys, offering more than 50 alloys, with additional capacity for slab production. Equipped with state-of-the-art infrastructure and equipment, the foundry achieves remarkable flexibility and diversity in its production processes. Sustainability meets innovation at Halcor’s foundry plant, where a focus on recyclability is paramount. The material consumption strategy prioritises the use of recycled materials, such as copper scrap, over primary materials. By incorporating cutting-edge technology to optimise the sorting process of scrap copper and a blending optimisation software, Halcor sets a high standard for sustainable manufacturing practices. The foundry exemplifies Halcor’s strong commitment to environmental responsibility and technological advancement. Operational Excellence has been seamlessly integrated into the Foundry Plant’s daily operations, driving ongoing employee engagement while reinforcing a culture of ownership, standardization, and a strong focus on zero defects.

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Halcor copper & alloys extrusion division of elvalhalcor aerial brass rods tubes plant

Brass Rods, and Tubes Plant

Our Brass Rods and Tubes Plant exemplifies Halcor’s versatility in metal production, showcasing our ability to meet diverse industry demands through innovative manufacturing. By maintaining stringent control over every step of the production process, we consistently deliver brass products that surpass the expectations of our global clientele. This facility not only underscores Halcor’s commitment to exceptional quality but also solidifies our position as a comprehensive provider in the metal industry, capable of addressing a wide range of specialized needs. Brass Rods, and Tubes Plant, the Operational Excellence Framework is embedded in daily activities, empowering employees to proactively identify and eliminate losses through consistent use of structured problem-solving and standardized processes.

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Halcor copper & alloys extrusion division of elvalhalcor Aerial foam insulation materials plant

Insulation Materials Production Plant

Our Insulation Materials Production Plant exemplifies Halcor’s expertise in creating advanced insulation solutions. By integrating traditional knowledge with modern technology, we design high-quality insulation materials tailored to various industry needs. Through precise control of production at every stage, we deliver products that exceed market standards for efficiency and dependability. It reinforces Halcor’s position as a trusted provider of innovative insulation solutions to address a wide range of applications, from construction to industrial requirements.

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Driving Operational Excellence through Innovation and Intelligence

Our Manufacturing Excellence Program is a framework rooted in globally recognized methodologies such as Lean Manufacturing, Six Sigma, TPM, TPS, TQM, and E2ESC. It is designed to elevate industrial performance by enhancing efficiency, minimizing waste, and promoting a culture of continuous improvement. Building on our foundation in manufacturing, we have expanded operational excellence across all functions by harnessing digitalization, automation, and AI capabilities throughout the entire value chain. At the heart of the program is our commitment to enhance customer satisfaction by delivering higher product quality, shorter lead times, and improved reliability- positioning our organization as a leader in operational excellence.
Key Objectives: Enhance Customer Satisfaction: Improve product quality, reduce delivery times, and increase reliability.

Ensuring Health and Safety Excellence at Halcor

At Halcor, occupational health and safety take center stage.

Through regular health and safety training, we equip our team with the knowledge and skills to recognize and prevent risks in the workplace. These initiatives foster a culture of awareness and preparedness, ensuring every employee operates with confidence in a protected environment. With a steadfast focus on continuous improvement, Halcor prioritizes creating a workplace where safety is never compromised.

HEALTH & SAFETY POLICY

Safety Measures

Halcor’s health and safety measures form the backbone of our operational excellence.

From rigorous risk assessments to safe working conditions, our approach aims at achieving zero workplace accidents or illnesses. Certified under ISO 45001:2018, our Occupational Health and Safety Management System enables us to monitor performance and implement effective improvements. We integrate advanced tools like the Intelex electronic platform for every incident (accidents, near misses, property damages) reporting and analysis, ensuring immediate actions are in place to uphold safety and well-being.

Employee Governance for Lasting Impact

At Halcor, we value collaboration in fostering a safe workplace.

We engage employees at all levels through consultation and participation in health and safety initiatives and action plans. Monthly safety inspections, dedicated monthly performance reviews, and robust governance structures drive accountability. By combining management oversight with team involvement, Halcor ensures health and safety protocols are not only implemented but deeply ingrained in our operational culture.

Leading By Example in Occupational Health

Halcor’s dedication to occupational health and safety sets us apart as an industry leader.

Through ongoing investment in training, risk assessment analyses, machines’ improvements, and safety innovations, we cultivate a sustainable culture of well-being. Our efforts are evident in the continued refinement of safety protocols, fostering trust within our workforce. For Halcor, safeguarding health and safety isn’t just a goal—it’s our unwavering commitment to the people driving our success.

Health & Safety Policy

At Halcor, our commitment to safety extends beyond our employees to encompass partners, contractors, visitors, and everyone who steps onto our premises.

Ensuring a safe workplace is a core objective, reflected in our proactive measures and dedication to health and safety excellence. Halcor supports employees participation in Health and Safety matters by introducing dedicated programs e.g. IDEA BOX, BEST Operational Excellence To learn more about our comprehensive approach and the principles guiding our efforts, we encourage you to explore our detailed Health and Safety Policy

READ THE POLICY HERE

Tailored Medical Exams for Comprehensive Care

We understand that every job role has unique physical demands.

That’s why Halcor provides comprehensive medical exams, customized to align with each employee’s duties and gender. These assessments not only monitor health but also proactively identify potential workplace-related issues. By integrating personalized care into our safety measures, we promote the well-being of our workforce while reinforcing our commitment to maintaining a healthy, productive environment for all.

Learn more about our Work Culture

Versatile Applications of our Products

Discover the wide range of industries and uses our products excel in.

HVAC & R

Industrial Applications

Electrical Applications

Building installations

Forging & Machining

Automotive

Renewable Energy