Automotive News 1/2015

­1 / 2015
In focus
MANN+HUMMEL
in the USA
 MANN+HUMMEL systems competence for the Ford Edge 2.7 liter V6
 Two-stage switchable oil circuit increases efficiency of the Volkswagen XL1
 Intake manifold for SGM Wuling with optimized torque curve
Contents
3
4
Preface
USA on the fast track
Preface
17
Acting globally – delivering locally
Air cleaner for the Indian market
Dear Business Partner,
In 2014 the media was dominated by news of political and
MANN+HUMMEL pursues a sustainable
18
Cutting CO2 emissions
growth strategy
Two-stage switchable oil circuit increases efficiency
social unrest. This influenced the economic situation of the
8
From mustangs and workhorses
of the Volkswagen XL1
affected countries and made market conditions more diffi-
Air cleaner systems for Ford
20
Power for the platform
International production network ensures supply
therefore all the more proud today to be able to report a
to customer locations
continued success story. Despite the described difficulties
22
Great performance in the smallest space
Optimum use of installation space thanks to radial
sealing system of MANN+HUMMEL
10
MANN+HUMMEL has the Edge
Systems competence for the
Ford Edge 2.7 liter V6
11
Delivering important and quantifiable
benefits
cult. As MANN+HUMMEL is a company with global operations, we were also affected by these developments. We are
we have been able to increase turnover in the business unit
automotive original equipment in comparison to the previous year for the fifth year in succession.
Intake manifold for SGM Wuling with optimized
24
The art of managing variants
This success story is, among other things, based on the
torque curve
Wide range of versions and tailor-made solutions
sales growth in Asia. In China and India we were able to
12
‘Our focus is on practical solutions’
for Nissan
increase the turnover of the previous year, with part of the
Interview with the Product Champions for Technical
26
At a glance
Plastic Parts and Intake Manifolds
Fuel filter for the modular transverse matrix
15
Charge motion
Fine-tuned flaps to increase flow efficiency
16
Organics against allergens
Cabin air filter with anti-allergenic effect
rise due to a new plant in Thailand which opened in 2014.
Turnover also increased in the European countries of
France, Italy and the Czech Republic.
(MQB) of the Volkswagen Group
Top performance for Volkswagen – even under
A further successful region was clearly the USA. Lower
unemployment, a stronger dollar and new car registrations
extreme conditions
MANN+HUMMEL IBÉRICA is exclusive supplier
back to the high level last seen before the financial crisis of
New plant in Rayong, Thailand
system solutions which reduce CO2 emissions (page 12). The
2008 mean that the American economy is currently doing
FreciousPlus cabin filter takes us close to the end customer.
well and therefore also MANN+HUMMEL is enjoying suc-
The filter protects the vehicle occupants against allergens,
cess in the region. This not without reason as we have been
bacteria and fungi (page 16).
investing in production facilities in the USA for nearly 20 years
and therefore we are able to offer customers low logistics
These new developments mean that also in 2015 we are
costs and extreme flexibility. The opening of our North Caro-
your partner for filtration in all areas, providing solutions to
lina Innovation Center in 2013 shows, that the whole US
challenges, from the concept right up to series production.
market is extremely important for MANN+HUMMEL. As a
result, this issue of the Automotive News will focus on the
Your Kai Knickmann
efforts, challenges and opportunities for MANN+HUMMEL
in the US market (page 4).
The relevance of new products, however, is not limited to
IMPRINT
North America. Innovative solutions are very important for
MANN+HUMMEL Automotive News;
subjects such as the statutory CO2 emission controls.
[email protected]
MANN+HUMMEL supports customers here with new pro-
Publisher: MANN+HUMMEL GMBH, 71631 Ludwigsburg, Germany
ducts for combustion engines. Heinz Bühl and Heinz Fuchs
Responsible in terms of German press law: Harald Kettenbach
explain in an interview how MANN+HUMMEL is working on
Editor: Birgit Herbst, Lisa Bürkle
Layout, production: Ralph Dodel Grafikdesign, 73066 Uhingen, Germany
2
3
Portage, Michigan
Sales, Engineering, Production
Seattle,
Washington
Sales
Bloomfield Hills,
Michigan
Sales, Engineering
Fayetteville,
North Carolina
Production
Raleigh,
North Carolina
Engineering, Sales
MANN+HUMMEL USA headquarter in Portage, Michigan
Dunlap,
Tennessee
Production
USA on the fast track
MANN+HUMMEL pursues a sustainable growth strategy
MANN+HUMMEL’s footprint in the United States of America
US customers consider MANN+HUMMEL as a benchmark for quality, security and innovation.
Read how the filtration specialist manages to meet current customer requirements and simultaneously prepares for the challenges of tomorrow.
This trend is supported by decreasing
upbeat mood and chances for growth
Detroit, the filtration expert has con-
unemployment, a stronger dollar, and
currently offered by the North Ameri-
tinually widened its radius within the
lower gasoline prices, which are even
can market.
North American market. Just one year
later, MANN+HUMMEL acquired the
lower than the price of a liter of drinking
water. The annual North American In-
How it all began …
company Geiger Technik, a specialist
In 2014 sales in the USA were con-
financial crisis eight years ago. De-
in comparison to the previous year –
ternational Auto Show in Detroit in the
For nearly 20 years MANN+HUMMEL
in the production of coolant and brake
siderably more than 16 million ve-
mand increased by 5.9 percent in re-
the USA continues to be a key market
middle of January 2015 also reflected
USA has pursued a successful growth
fluid reservoirs in Portage, also lo-
hicles. This is a very positive develop-
lation to 2013. With an expected pro-
for growth and investment in the auto-
this development. The high number of
strategy in North America. Starting
cated in Southwest Michigan. This
ment when considering that sales
duction volume of 11.9 million auto-
motive industry.
new vehicles exhibited, especially
with the sales office established in
enabled the company to use the ex-
were at the same level before the
mobiles in 2015 – a plus of 4.2 percent
entry-level luxury cars, confirms the
1996 in Farmington Hills, a suburb of
isting production facilities and func-
Purchase of
Geiger Technik in
Portage, Michigan
Expansion of
production and
office area in
Portage, Michigan
Purchase of the
Automotive Air
Induction Systems
and Technical
Parts division of
the Solvay Group
Joint acquisition
of Purolator Filters
NA with the
Bosch Group
1996
1997
1998 – 2001
2002
2006
2009
MANN+HUMMEL started a footprint
in the USA
Won business
for manifolds with the customer
request to produce
in the USA
Establishment of
aftermarket organization in the USA;
2001, the total
production area
was 95,000 sq ft
Acquisition
improved
MANN+HUMMEL's global footprint
for plastics
manufacturing
MANN+HUMMEL became 50% owner of Purolator Filters NA
Fayetteville, North
Carolina
More space was required as the market started
to grow again
after the economic
downturn
Established a
sales office in
Farmington Hills,
Michigan
4
Opening of
Portage
Distribution
Center (PDC) in
Portage,
Michigan
Expansion of
production area in
Portage, Michigan
Opening of
production facility
in Dunlap,
Tennessee
2010
2012
Launched electric
vehicle battery
component
production
Strategic decision to open a southern plant to service regional customers
Acquisition of
Purolator Filters
NA in Fayetteville,
North Carolina
Inauguration of
the North Carolina
Innovation Center
(NCIC)
2013
Purolator Filters
NA belongs
100% to
MANN+HUMMEL
now
Measure to
improve the
collaboration
between industry
and science
Opening of South
Campus in
Portage, Michigan
2014
Second production facility in
Portage due to
further won orders
5
Production technology of MANN+HUMMEL USA
MANN+HUMMEL can produce its whole product portfolio in the USA due to its local production capabilities. Thanks to
the continuous enhancement of production technology, complex products can be realized in the highest quality. Current
main products are air cleaner systems, intake manifolds, and battery trays.
Applied plastic processing processes:
Injection molding (250 ton to
1300 ton)
-Overmolding of blow molded ducts
-2-shot molding
North Carolina Innovation Center (NCIC)
-Injection molded bellows
tioning management structure. In the
names from the world of business and
improve manufacturing efficiency and
following years the increasing number
science. This gives MANN+HUMMEL
provide space for future growth. A
of orders from large customers en-
USA the possibility to work even closer
short service road connects the two
-3D suction blow molding
abled the steady expansion of the pro-
with its customers. Also, with three large
Portage plants into one campus,
-2D blow molding with capability to duction and office space in Portage.
universities in the immediate vicinity,
which is successfully able to meet the
run high temperature materials (PA)
there is a continual exchange of in-
increasing demands of US customers.
Blow molding (4 liter to 8 liter)
The next step, which would have a
formation among the academic insti-
long-term influence on the North
tutions and MANN+HUMMEL’s inno-
‘The opening of our new South Cam-
-Rotation welding
American market, came in 2002 when
vation center.
pus building gives us the space for
-Hot plate welding
current business and for future busi-
-Vibration welding
MANN+HUMMEL acquired the Automo-
Welding
tive Air Induction Systems and Techni-
In other fields MANN+HUMMEL is also
ness opportunities,’ said Kurk Wilks,
-Hot gas welding
cal Parts division of the Solvay Group.
benefiting from the current growth trends
Vice President and General Manager
-Laser welding
Then in 2006 the North American filter
in the USA. In addition to several new
MANN+HUMMEL USA about the new
manufacturer Purolator Filters NA was
product launches at the Dunlap and
220,000 square-foot facility. ‘Our new
taken over in a joint venture with the
Portage facilities, in September 2014,
building is a great example of our stra-
Bosch Group. MANN+HUMMEL took
a second production facility was opened
tegic growth plan in action. By provid-
full ownership in 2013. Thanks also to
in
This project allowed
ing innovative solutions to our custom-
these acquisitions MANN+HUMMEL
MANN+HUMMEL to bring its distribu-
ers we will continue to grow aggres-
is today one of the most important
tion center closer to its main facility,
sively in the automotive industry.’
Portage.
Automated and manual clean room assembly in Portage, Michigan
and air cleaner systems in the USA. In
Award confirms good customer
relationship
the meantime the MANN+HUMMEL
In 2015, the MANN+HUMMEL Group
group has nearly 2,000 employees in
was named 2014 Supplier of the Year
the USA working at six locations in the
by General Motors. A special point of
development, production and distri-
the award is that MANN+HUMMEL
bution of products. The importance of
has now received it for the twen-
the
for
tieth time. For the employees of
MANN+HUMMEL is also underlined
MANN+HUMMEL, the award confirms
by the inauguration of the North Caro-
the success of their strategy geared to
lina Innovation Center (NCIC).
closeness to the customer, quality,
manufacturers of intake manifolds
North
American
market
and service. In addition, GM has
Ready for the challenges of
tomorrow
accorded the company the status
The innovation center opened in 2013
the business relationship between
and is located directly on the campus
MANN+HUMMEL and GM. Only 28 out
of North Carolina State University in
of 78 honored suppliers received this
Raleigh. It is situated in the ‘research
recognition as they fulfill the high qua-
triangle’, a region in North Carolina which
lity requirements of the customer. 
of ‘Prime Supplier’, which supports
has numerous academic research
centers and therefore attracts big
6
Ribbon cutting ceremony of the new South Campus facility
Supplier of the year award, Brandon S. Vivian, Mark Lauzon, Kai Knickmann and Wade Sheffer (f.l.t.r.)
7
The complete air cleaner system for
both vehicles includes the dirty air
Managing global challenges successfully
Photo: © Ford Motor Company
ducts, air cleaner and the clean side
ducts. MANN+HUMMEL produces
Vehicle manufacturers are increasingly working in a global environment.
the systems in Portage (Michigan) and
Customers and suppliers are located around the world, which requires glo-
Dunlap (Tennessee). The air filter ele-
bal players to be flexible and rely on their global business partners. In recent
ment is supplied by MANN+HUMMEL
decades, MANN+HUMMEL has invested substantially in its engineering so-
Purolator in Fayetteville (North Caroli-
lutions and products across the key continents and established a global
na), a company taken over from a joint
footprint in terms of engineering technology, capacities and manufacturing
venture
and
expertise. This strategy has enabled MANN+HUMMEL to support cus-
MANN+HUMMEL in 2013. This allows
tomers as they face the challenges which go along with a more demanding
the filtration specialist to provide an
international environment and help them meet their ambitious targets.
between
Bosch
even more complete service to customers in the USA.
New Ford Mustang - the ionic ‚pony car‘
Foto: © Ford Motor Company
From mustangs and
workhorses
The 1960’s were significant years for the global motor industry and one car launched at that
time, was to gain iconic status – the Ford Mustang. Considered to be the original ‘pony car’ it
continues to be revered and sought after today as it was decades ago. MANN+HUMMEL has
enjoyed a close working relationship with Ford Motor Company over the years. To the joy of the
company the latest Mustang is again equipped with an air cleaner system developed and supplied by MANN+HUMMEL.
The Ford workhorse: F150 pickup truck
The fruitful relationship between the
Besides
two companies includes the supply of
MANN+HUMMEL supplies a sound-
air cleaner systems for Ford’s global
pipe to feedback additional sporty
B-car vehicles – the Fiesta, EcoSport
sound from the engine to the passen-
and B-MAX – and the global CD-
ger compartment. This remarkable
vehicles including the Fusion, Edge,
acoustic feature is for the 5.0 liter V8
Mondeo and Galaxy. However, this is
engine and makes the Mustang sound
not the end of the list: the highly suc-
even more sporty and ‘muscular’. 
the
air
cleaner
system,
cessful F150 pickup truck – part of the
F-Series, America's best-selling truck
for 38 straight year – is also equipped
with air cleaner systems developed
and supplied by MANN+HUMMEL.
Key to this business relationship is the
company’s ability to provide local
technical engineering, production support and supply.
8
Air cleaner system and soundpipe for the Ford Mustang 5.0 liter V8
Air cleaner system for the F150 3.5 liter V6 bi-turbo
9
MANN+HUMMEL has
the Edge
Delivering important and
quantifiable benefits
A classic co-development partnership between Ford Motor Company and MANN+HUMMEL, has
The intake manifold on a vehicle is increasingly becoming an important area of innovative de-
resulted in air cleaner systems for all available engines as fitted to the popular Ford Edge and
velopment, with the objective of improving performance and fuel economy as well as working
Lincoln MKX, to be sold in more than 100 markets globally including North America and China.
towards meeting the ever more demanding and stringent CO2 environmental emission targets.
Besides the 2.0 liter 4-cylinder and the 3.5 liter V6,
MANN+HUMMEL engineers have considerable experience
An appropriately designed variable intake manifold system
MANN+HUMMEL also supplies components for the 2.7 liter V6.
in the area of air cleaner system design and plastic process-
can also be used to improve efficiency in ranges relevant for
The total system package includes the dirty air duct, the air
ing. This has led to a significant technical development – the
drive cycles. In this case the manifold design must be opti-
cleaner housing with an air filter element and the two clean
introduction of TPE injection molded bellows instead of
mized over the whole engine mapping range.
side ducts guiding the air to the respective turbo charger.
using a blow molded bellow or a rubber part. In addition to
other advantages they deliver a cost reduction and high
The effect which is used to improve the efficiency is called
acoustic performance.
pulsation charging. The intake stroke of the piston combines
with the opening of the intake valve thereby creating an under
The principle advantage of this development is the solution
pressure pulse which runs along the runner to the plenum.
of contradictory targets. On the one hand, high collapse
At this stage the pressure pulse delivers an over pressure
robustness requirements lead to high wall thicknesses.
effect which runs back to the cylinder for better engine torque.
On the other hand, good decoupling behavior requires small
Intake manifold for SGM Wuling
The higher the rpm the faster the opening and closing of the
intake valves. This in turn leads to the requirement of a shor-
wall thicknesses especially in the bellow area. By applying
the TPE technology, a softer material is used and the de-
MANN+HUMMEL has been at the forefront of developments
ter runner to match the open valve and the reflected over
coupling is improved. The precisely defined inner wall thick-
in this area by employing innovative designs in switchable
pressure pulse.
ness results in reduced push-on forces of the bellow section
systems and variable runners lengths within the intake mani-
and a reduced noise radiation, an increasingly important
fold to deliver major benefits.
Switching point
consideration.
manding work has been the supply of an active intake mani-
developing air cleaner systems together with in-depth
fold for the Chinese vehicle manufacturer SGM Wuling. The
material know-how, MANN+HUMMEL became an ABF
company is a joint venture business involving General Mo-
(Aligned Business Framework) partner to Ford. The com-
tors, Shanghai Automobile Industry Co. and Liuzhou Wuling.
pany is able to provide engineering support and inno-
It has become China’s largest automaker specializing in uti-
The dirty air duct is produced using a 2K rotary injection
vative ideas from a variety of technical centers across the
lity vehicles for rural markets. The intake system outlined
molding process, considered to have best-practice status
globe. Furthermore, MANN+HUMMEL offers a worldwide
here is fitted to the Wuling Hong Guang B12 platform model
MANN+HUMMEL systems competence for the Ford Edge 2.7 liter V6
and is, therefore, carried over for other applications. The air
production network using globally uniform standards. This
which has a 1.2 liter 4-cylinder gasoline engine. As indicated
cleaner housing contains a filter element with a plastic grid
has enabled the filtration specialist to become a leader in
the technical work was undertaken by MANN+HUMMEL
for higher stiffness, a particularly important consideration
developing and delivering professional and reliable systems
engineers based at the company’s Shanghai engineering
when the filter element is wet. The air cleaner cover incorpo-
at a global scale.
center whilst the production of the system was carried out at
the company’s Chinese plant at Liuzhou.
rates a pressure sensor as well as the two air outlets to the
Torque
The most recent result of this innovative and technically deThanks to a wide production portfolio and many years of
Engine speed
Long runner
Main air path
Short runner
Resulting torque curve
Optimized torque curve through length adjustments
The intake manifold in this application exploits the extensively
proven technology of variable runner length intake manifolds.
two clean side ducts. Each clean side duct consists of an
The Ford Edge systems developed and produced at the
injection molded TPE (thermoplastic elastomer) bellow and
MANN+HUMMEL USA facilities in Portage (Michigan) and
Recognition of the work by MANN+HUMMEL engineers re-
The key to the system’s success is the switching principle,
a blow molded duct section. Further, it includes an elbow
Dunlap (Tennessee) are part of many air induction systems
sulted in the intake manifold being honored, with a coveted
whereby the plenum is connected to the short respectively the
piece with absorptive broad band silencer directly in front of
the company is producing for Ford. 
Environmental Production Award at the 2014 China’s Auto
long runner. The switching between the different runner lengths
the turbo charger inlet. This prevents the high frequency
and Auto Parts Industry Innovation Awards. Variable intake
is achieved by a rotary valve in order to minimize the dead
noise of the turbo charger from entering the environment via
manifolds are typically used to improve full load performance
volume inside the component. The rotary valve is activated
the air induction system.
and partly to lower fuel consumption in the part load range.
by a vacuum actuator controlled by a solenoid valve. 
10
11
‘Our focus is on practical
solutions’
Resonance charging, integrated charge air cooler, thermal management, integration of
electrical supplemental charging – MANN+HUMMEL uses innovative technology to help the
international automotive industry achieve CO2 targets. Product Champions for Intake Manifolds and Technical Plastic Parts from the system supplier provide functional support to ensure
the right focus. We spoke to Dr. Heinz Fuchs and Heinz Bühl about current trends and new
technologies.
Mr. Bühl, Mr. Fuchs, what are the
Why is your work special?
responsibilities of a Product
Champion?
how and its interaction enables us to
improve current products and develop
Fuchs: An important point is our
new products. Our focus, however, is
cross-functional technical responsi-
on practical solutions and our projects
Bühl: As Product Champions we take
bility. Therefore we regularly exchange
actually come to market.
on a cross-functional role. We are
information with the R&D depart-
entrepreneurs within the enterprise.
ments of our customers. We also work
What are the advantages for
We are responsible for our product
closely together with pre-develop-
customers?
groups, starting with the strategy
ment departments concerning future
right up to the products in the pro-
engine generations and requirements
Bühl: Customers benefit from our in-
duction. That‘s a big challenge, but it‘s
and use this information to derive
tegrated approach. When we start
also fun and we can make a difference.
strategies and future areas of activity.
working on a new innovation or product idea we think carefully right from
the start about how this can be imple-
Interview with the Product Champions for Intake Manifolds (Heinz Bühl, left) and Technical Plastic Parts (Heinz Fuchs, right)
mented so that afterwards the product is economic to produce and func-
dern engine concepts to reduce con-
What solutions are currently being
cerns maximizing the amount of
tions reliably.
sumption. Examples here include effi-
developed?
torque available at low engine speeds,
so-called low-end torque. For this
cient oil separators for crankcase venThe subject of reducing CO2
tilation or switching valves for low
Bühl: An interesting solution for down-
purpose we have developed an active
emissions remains very
pressure exhaust gas recirculation.
sizing is our intake manifold with inte-
charge air duct where we can switch
important. What solutions can
Less weight, lower friction losses or
grated charge air cooler which helps
the charge air line to exploit the
MANN+HUMMEL offer here?
«
Fuchs: Ultimately the focus in Europe
as in the USA and Asia is on how to
further reduce the fuel consumption of
MANN+HUMMEL products support engine technology geared
to lower consumption. Dr. Heinz Fuchs
vehicles. Here in the areas of air and
»
liquid management we have convinc-
Active intake manifold
system with integrated
charge air cooler and eBOOSTER
12
What are the
ing answers and products. Some new
reduced pressure drop, higher com-
us to further increase the efficiency of
pulsation in the intake system. The
customer require-
products such as our ACT valve for the
pression and greater variability in the
the turbocharging. This can save up
integration of the electric booster in
ments? What functional-
high precision switching of cooling
intake tract: MANN+HUMMEL products
to three grams of CO2. Recently our
the intake tract works along similar
ity is required? Which expertise
circuits or weight-reducing components
support engine technology geared to
highly integrated solution was suc-
lines. This electrically-driven addi-
and product ideas can we bring in?
directly reduce CO2 emissions. Other
lower consumption.
cessful in landing two series orders.
tional charging exploits a leverage
This cross-functional system know-
new products enable the use of mo-
The subject of down-speeding con-
effect with the result that ten times
13
where it is needed and this lowers
The Product Champions
consumption by up to one or two
Heinz Bühl studied mechanical engineering and initially worked for 12
percent.
years in the development of engines. He has worked for MANN+HUMMEL
since 2001 and holds the position of Vice President Intake Manifold
How do things look in the area of
Systems. As a Product Champion he has global technical and commer-
electric cars?
Charge motion
Fine-tuned flaps to increase flow efficiency
cial responsibility for the product segment intake manifolds.
Fuchs: In our opinion, the hybridizaDr. Heinz Fuchs studied physics and economics in Germany and in the
tion of the intake tract particularly
USA. He has lectured at the University of California in Berkeley and has
offers a high potential. For this we
worked for Bosch in the area of research and product development.
offer a whole range of products for the
He joined MANN+HUMMEL in 2009, with initial responsibility in the area
air conditioning of batteries: battery
intake manifold for the group’s 1.8 liter and 2.0 liter TFSI engines. The latest version of this com-
of production and product management, and since 2010 he holds the
trays, degassing units and drying and
ponent produced internationally in high volumes is characterized by sophisticated technical
position of Vice President Technical Plastic Parts.
deionization components. Taken to-
details and an even more robust design.
gether this allows the use of hybrid
MANN+HUMMEL already supplies Volkswagen with the third generation in a row of its active
vehicles which in turn reduce CO2
emissions.
the applied electric power can be
charge air duct be connected well
generated on the crankshaft through
enough to an intake manifold as re-
How well is MANN+HUMMEL
new concept enable even greater ro-
increased air in the combustion cham-
quired for resonance charging. If real
prepared for the future?
bustness and improve the perfor-
ber and more injected fuel.
driving emission controls come, we
Furthermore, improved details in the
mance of the component. One example
will need such new solutions to meet
Bühl: In the area of air intake manage-
Does plastics technology also have
the requirements, to be able to main-
ment and liquid management we have
further potential?
tain driving fun and to do all this for an
a number of solutions which directly
affordable price. For the OEM it is
reduce consumption and CO2 emis-
Fuchs: Yes, today, besides producing
attractive to invest in these products
sions. Other products used as en-
liquid filter modules and air cleaner
as they further improve the efficiency
systems in plastic, also intake mani-
of the engine. This
folds, charge air ducts, oil sumps,
is where our pro-
ponents with regard to on-board diag-
cylinder head covers and other pe-
ducts as en-
nosis (OBD-2) of the California Air
ripheral products are being success-
abling techno-
Resources Board (CARB).
fully developed and manufactured in
logies often fa-
The charge motion flaps of the intake
The tub-shaped flaps offer other
plastic. This enables our customers to
cilitate the imple-
manifold are a technical highlight.
technical finesses. In addition to the
With the aid of a magnet sensor the
reduce weight through material sub-
mentation of engine
Their task is to bring high turbulences
standard tumble flaps, the 1.8 liter
third generation intake manifold has
stitution and also the addition of new
developments which lead
to the air/fuel mixture when streaming
and 2.0 liter TFSI engines also have
contactless position feedback and is
functions and integration possibilities.
to lower emissions.
into the combustion chamber. On the
so-called drumble flaps. These flaps
therefore free from wear. Both, the
one hand this leads to higher torque
have a special cut-out which gives the
magnet sensor as well as the retainer
are the plastic flaps molded onto a
Generation 3 (2014)
Generation 2 (2007)
continuous stainless steel shaft. Another detail is that the component is
equipped with position feedback from
the
Generation 1 (2004)
Overview of the three generations of the TFSI
intake manifold
shaft
to
the
rotary
sensor.
MANN+HUMMEL therefore meets the
requirements for exhaust gas com-
Bühl: The further development of ma-
Are there some examples of this
at low engine speed and on the other
air flow an additional swirl (swirl and
integrated directly in the shaft make a
terials, high-temperature resistant ma-
enabling approach?
hand to less emissions of CO2 and
tumble = drumble). This leads to a
contribution to the increased robust-
other harmful gases.
further improvement of the filling of
ness. In addition, the shielding of the
the cylinder.
sensor chip was improved and the
terials and hot gas welding today enable wall thicknesses of just two milli-
Fuchs: One example is the oil separa-
meters. This thinner wall thickness and
tion of the crankcase ventilation. In-
a higher structural strength usually
creasing turbo pressure and strong oil
save up to 20 to 25 percent weight.
vapor require a high oil separation
For a current intake manifold, for ex-
efficiency. This alone does not lower
abling technologies allow our cus-
used to optimize the air flow. They
The part developed in Ludwigsburg is
ample, this has been 1.2 kg.
CO2 emissions, but it allows higher
tomers to implement their new tech-
have the advantage that in the open
produced at the MANN+HUMMEL
turbo pressures, higher oil viscosity,
nology with combustion engines and
position they rest against the side of
locations in Shanghai (China) and
and even greater fine-tuning of the
electric transmissions. Our new pro-
the intake manifold and are not in the
Sonneberg (Germany). As the 1.8 liter
combustion process. A further possi-
ducts are partly already on the mar-
middle of the air flow as with conven-
and 2.0 liter TFSI engines are fitted in
Bühl: In order to achieve more in the
bility is thermal management which
ket, will be ready for launch in the
tional straight charge motion flaps.
future, we will have to find a new sys-
we use to optimize the thermal re-
coming years or are still in the pre-
This prevents undesirable turbulences
tem approach and question how sys-
serves of the engine. We direct
development phase. So the prospects
of the air and reduces the pressure
tems interact. For example, can a
energy from where it is generated to
are exciting. 
loss.
Can we do more in the future?
14
Active charge air duct from MANN+HUMMEL
Just as with the intake manifold of the
mounting of the rotary sensor simpli-
second generation, improved charge
fied through a clip fixing.
motion flaps with a tub shape are
‘Swirl’
‘Tumble’
Schematic illustration of different flow profiles
of the air/fuel mixture in the cylinder
almost all of the models of the Volkswagen group, the intake manifold is
produced in very high volumes. 
15
Organics against allergens
Cabin air filter with anti-allergenic effect
Acting globally –
delivering locally
According to reports from the World Health Organization, allergies are the fourth most
MANN+HUMMEL presents a new air cleaner which has been developed by a global team
frequent chronic illness in the world. The inhabitants of larger cities and industrial locations are
specially designed for the requirements of the Asian market. Today, this air cleaner is produced
endangered by air pollution including various particulate matter or corrosive gases.
locally at three plants in Asia.
For passengers prone to allergies,
Besides China and India, especially East Asian markets like
As a consequence, the system has fewer parts and is, there-
pollen, bacteria, fungal spores and
Thailand, Indonesia and Malaysia are classified as growth
fore, more cost effective to produce, an important consid-
other particulate matter in ve-
markets. Many truck manufacturers strengthen their local
eration for our customers. To protect the engine during its
presence in these cost sensitive markets among other things
operational life, MANN+HUMMEL developed a patented air
1
hicles can trigger an allergic re-
Particle filter
layer
by building new production facilities. One expectation of our
cleaner design. This ensures the use of original equipment
phere, these are able to enter
customers is that MANN+HUMMEL as a global acting sup-
service (OES) elements fulfilling the OEM specification re-
the passenger compartment
plier is able to manufacture its product portfolio locally and
quirements regarding filtration efficiency, dust holding capa-
therefore can support the customers directly. At the same
bility and quality. In addition, the part is robust in design and
time, these products have to deal with the challenging
lighter in weight, facilitated by moving away from traditional
environmental issues where the vehicles will be operating.
steel to molded plastic housings.
action. If present in the atmos-
2
via the ventilation ducts as
conventional cabin air filters only hold back pol-
Premium
activated
carbon layer
len and dust particles.
One example of a successful product realization is the
This is exactly where
3
the new cabin filter
Frecious-Plus from
Biofunctional
layer
MANN+HUMMEL air cleaner system that fulfills these
The material specified by MANN+HUMMEL is a glass-fiber
criteria.
reinforced polypropylene, tried and tested over many years
in air cleaner housings for commercial vehicles. The material
MANN+HUMMEL
can withstand the tough and demanding climatic and road
comes into play. A spe-
conditions likely to be experienced in this application.
cially developed biofunctional
FreciousPlus with three filter layers
filter layer has anti-allergenic and anti-
The air cleaner has been developed in global cooperation
microbial characteristics.
within the engineering network of MANN+HUMMEL. Thus, a
development team from facilities in India worked with
The biofunctional anti-allergenic effect is achieved using a
The cabin filters in the current MANN+HUMMEL range of
Chinese engineers as well as with a team from the newly
polyphenol coating. Polyphenols are natural products which
products do in fact already include a highly efficient particle
created plant in Thailand. Working closely together and
have a positive effect on health. They are found in various
filter layer which filters out coarse particles such as pollen
drawing on the experience and expertise of the company’s
plants such as green tea, apples, grapes or pomegranates
and smaller particles or soot. However, the relevant aller-
engineers in Germany, MANN+HUMMEL developed an
and include the ability to absorb albuminous substances
genic particles which are located within the inside of pollen
innovative air cleaner which is now produced at three
such as allergens whereby these then become inactive and
and which can endanger the health of the car passengers
MANN+HUMMEL plants.
are therefore no longer dangerous.
are frequently even smaller (in the nm range). Therefore they
can advance through this layer and with conventional cabin
Patented air cleaner for the Indian market
professional cooperation during the development and pro-
Through an additional anti-microbial coating, FreciousPlus
filters enter the inside of the vehicle. If contact with the filter
also prevents the formation and breeding of partly unpleas-
media surface or other particles as well as other external
To provide a system that has a long service interval and is
ant smelling bacteria and fungi (e.g. molds) which trigger
influences such as moisture, heat or coldness stimulate the
able to cope with extremely dusty environments, our filtra-
allergies resulting from the accumulation of dirt and moisture
pollen, dangerous allergens can be released. The anti-aller-
tion experts integrated a dust pre-separator. This solution
on the cabin filter. It has been proven that this prevents
genic capability of the FreciousPlus cabin filter can demon-
has already proven successful with regard to other applica-
more than 98 percent of fungi and bacteria from breeding or
strably reduce the activity of the released allergens and so
tions for commercial vehicle and construction machines in
growing. Furthermore, the anti-microbial coating acts as a
reduce their potential to trigger allergies by more than 98
dusty regions. Unlike more traditional and conventional air
shield for the natural polyphenols since these as a natural
percent. In order to reliably protect car passengers, experts
cleaner vehicle installations for the Asian market; the new
product can easily be decomposed by the existing micro-
increasingly recommend the use of anti-allergenic cabin
system does not require a costly separate component in the
organisms.
filters. 
dirty side of the air duct.
16
The successful realization of the product shows that the
duction works out. 
17
A particular advantage is the integration of the solenoid valve in the oil
Cutting CO2 emissions
module which is already available on
the engine. The oil filter module developed by MANN+HUMMEL for the
Two-stage switchable oil circuit increases efficiency of the Volkswagen XL1
VW group has the central function of
controlling the oil circuit and protecting the components from wear and
particularly at full throttle against high
temperature loads. The functions of
The switching of oil circuits offers potential to further reduce CO2 emissions. Especially with
the oil module include efficient oil
regard to mandatory emission targets for Europe in 2020/2021 the reduction of these emissions is
filtration and oil cooling and also the
gaining in importance. MANN+HUMMEL supports car manufacturers to cut CO2 emissions with a
solenoid valve to control the oil pump.
newly developed oil filter module. It is equipped with an integrated solenoid valve to control the oil
‘In order to fully exploit the potential to
pump and has been especially designed for the Volkswagen XL1.
reduce CO2 emissions in the future,
we will continue to further develop the
system and oil circuit’, explains Stefan
meter. With a fuel consumption of only
to meet the EU target values of 95
0.9 liters of diesel fuel, the XL1 is the
cuit which, depending on engine load
grams of CO2 per kilometer. The value
series
level, regulates the pressure between
is initially valid for new vehicles and
consumption in the world. Its drive
from 2021 will apply to the whole fleet.
combines a two-cylinder TDI engine
Using so-called ‘super-credits’ for the
with 35 kW/48 PS, a 20 kW/27 PS
The combination of a variable oil
production of cars with a particularly
electric motor, a lithium ion battery
pump with a solenoid valve allows
low fuel consumption the manufac-
and a 7-gear dual clutch transmission.
operation of the oil circuit in a high
turers will be able to compensate the
The XL1 has a radius of 50 kilometers
pressure stage and also in an energy
CO2 values of models with a high en-
using only electrical power.
saving lower stage. In case of lower
car
with
the
lowest
fuel
two levels.
This represents a strong incentive for
In the further development of com-
valve therefore switches the oil pump
the development of drive systems
bustion engines the focus is on the
in reaction to a pressure signal into
which are extremely energy efficient.
reduction of power loss. Engineers
the lower pressure stage. Thanks to
are working intensively on the best
the reduced power required for the
An excellent example of this is the
possible design of the oil circuit to
oil pump the fuel consumption is
Volkswagen XL1 plug-in hybrid which
obtain the perfect balance between
reduced.
only emits 21 grams of CO2 per kilo-
Systems at MANN+HUMMEL.
The MANN+HUMMEL oil filter module with an integrated solenoid valve enables the efficient
operation of the variable oil pump
Engine lubrication
points
engine speed range the solenoid
gine capacity over the fleet average.
Uhl, Product Manager for Liquid Filter
Solenoid valve
Oil cooler bypass valve
A
efficient lubrication and power loss.
Signal from the engine control
unit (ECU)
P
Oil/water heat exchanger
(Oil cooler)
T
Return check valve
Photo: © Volkswagen AG
The fuel-efficient XL1 – The new 1-liter car from Volkswagen
Signal for pressure level
preselection
Filter bypass valve
Oil filter
A: Working channel – Pressure signal
to oil pump
Functional range of the oil filter module
From 2020 on car producers will have
One solution is the switchable oil cir-
Variable oil pump
P: Pressure channel – Pressure from
main oil gallery
T: Ventilation channel – Ventilation
into crankcase
Oil sump
The smart oil circuit reduces the power loss and thereby increases the efficiency of the engine
18
19
Bellow with elastomere
sleeve to dampen the
noise emission
Bellow with elastomere
sle
sleeve to dampen the
no
noise emission
Side branch
resonator
Socket for plug-in air
flow sensor
Clean air duct
Connection for
heating pipe
(optional) of the
crankcase
ventilation system
Air cleaner
housing
Side branch
resonator
Air cleaner housing,
upper part
Integrated fixing point for
battery cable
Rectangular radial sealing air
filter element with pre-fleece
Air cleaner housing,
lower part
Optional cold country version:
secondary opening with vacuum
valve
Dual-flow,
clipsed dirty
air duct
Dual-flow, clipsed dirty
air duct
MANN+HUMMEL air cleaner system
MANN+HUMMEL air cleaner system customized to the engine compartment of the new MINI
Power for the platform
International production network ensures supply to customer locations
Car producers are increasingly adopting a platform strategy: MANN+HUMMEL supports this
The platform has a high number of
The cold country variations of the air
For the production technology the de-
identical parts for petrol and diesel
cleaner system are fitted with a com-
signers opted for a combination of in-
engine models. This allows efficient
pact under pressure valve which
jection molding and blow molding
implementation of all platform ap-
opens when the filter is clogged with
with different welding processes. The
plications. In order to meet the re-
snow and sucks air out of the
system supplier, for example, uses an
quirements of the different engines,
snow-protected engine compartment
infrared welding process to weld the
MANN+HUMMEL supplies variations
through a secondary opening. The
bellows to the clean side duct and hot
of dual-flow dirty side ducts which are
pre-fleece seals the snow protected
gas welding to attach the broadband
partly equipped with air guidance ribs
chamber of the air cleaner against the
silencer. 
on the inside.
main chamber.
Innovation from MANN+HUMMEL – the rectangular radial sealing system
with its system and acoustic expertise and will supply the BMW 1 series, 2 series and MINI
models with a modular air cleaner system in series.
Air cleaner
cover
Air cleaner
cover
Advantages at a glance:
AXIAL
sealing
RADIAL
sealing
Less components
Space-saving
Less weight
The complex air cleaner system is
In the development of the compo-
The radial seal between the rectan-
characterized by high efficiency, a
nents MANN+HUMMEL is able to ex-
gular air filter element and the housing
compact design, elaborate acoustic
ploit its comprehensive system and
is a technical highlight. This solution
design and an innovative and ser-
acoustic expertise. All the compo-
reduces the required number of
vice friendly radial sealing system. A
nents are designed to minimize pres-
screws, saves weight and simplifies
global R&D and production network at
sure loss and support best perfor-
servicing. With diesel engines and
more than 50 locations enables
mance of the engines. Depending on
cold country variations a pre-fleece
MANN+HUMMEL to efficiently supply
the variation, the high acoustic re-
extends service life. Despite its high
The utilization of the rectangular radial sealing system reduces the applied sealing forces between the upper and lower
its international customers in the
quirements are met through the care-
functionality, the compact component
part of the air cleaner housing to a minimum. The number of conventionally used screws can therefore be reduced or
automotive industry. The project for
ful minimization of sound radiation via
fits elegantly in the tight installation
eventually eliminated completely. This not only saves valuable installation space but also reduces the number of com-
the BMW Group involves R&D and
the clean side duct by finely tuned
space.
ponents, reduces the overall weight and enables as easy tool-free service of the filter element.
production locations in Changchun
broadband silencers, a generously
(China), Wolverhampton (United King-
dimensioned side-branch resonator
The modular air cleaner system finds
Another application example of the radial sealing can be found on the pages 22/23 
dom), Ludwigsburg, Bad Harzburg
and an elastomer sleeve over the
application
and Marklkofen (Germany).
bellows.
4-cylinder diesel and petrol engines.
20
with
3-cylinder
Snap-fit
Easy service
Self forming
screw
Air cleaner
housing
Air cleaner
housing
Conventional sealing
Radial sealing
and
21
Great performance in the
smallest space
The Chrysler Jeep range has achieved iconic status and a reputation for rugged and go
* No screw fixing
Air cleaner housing
*
anywhere performance. The Renegade, the latest small SUV in the Jeep range and the first
Jeep to be manufactured outside the United States, benefits from industry leading technology
developed and supplied by MANN+HUMMEL.
Clean side duct
Optimum use of installation space thanks to radial sealing system of MANN+HUMMEL
air cleaner housing a section of the
It is increasingly important with to-
Outlook
volume is separated by a wall. Set in
day’s automotive vehicle technology
Similar systems using the same de-
this section are two mushroom valves.
that systems are modular adaptable.
sign concept will be used for other
A pre-fleece on the filter element seals
This was a crucial objective by
vehicles being produced on an inter-
the section from the main area of the
MANN+HUMMEL
when
national basis. This includes two ve-
air cleaner. Should the main area of
designing this air cleaner system,
hicles to be made at the company’s
the system become clogged with snow,
which has the capability of being in-
Chinese factory, three vehicles pro-
the pressure from the engine forces
stalled in other Fiat Chrysler models
duced in Brazil and one in Mexico,
the mushroom valves to open up a
such as the Fiat 500x in Italy and the
together with potentially one new ve-
secondary air inlet. Located in the
Fiat Doblò in Turky (known as RAM
hicle to be manufactured in India. The
engine compartment, it is protected
ProMaster City in the US).
adaptability and flexibility incorpo-
engineers
from snow and allows the air cleaner
Compact air cleaner system from MANN+HUMMEL
rated into the MANN+HUMMEL air
system to work normally. This is
As
a
complete
system
supplier
cleaner design, plus the company`s
particularly important for a rugged
MANN+HUMMEL is also providing blow-
ability to supply globally, makes it the
off-road vehicle which must operate in
by hoses for diesel engine versions
nominated supplier across the various
all road and weather conditions.
fitted with or without heating pipes.
Fiat Chrysler Automobiles plants. 
Described as one of the most capable
system of compact dimensions, for
there are no screw fixings, a key fea-
small SUVs on the market, the Jeep
both diesel and gasoline engines. This
ture of the rectangular radial sealing
Renegade is strongly focused on clever
has been achieved by employing
system. Because no screw fixing is
design elements. The air cleaner sys-
MANN+HUMMEL`s rectangular radial
required the air cleaner can be posi-
tem embraces this concept by utiliz-
sealing system technology. Of course
tioned hard up against the side of the
ing MANN+HUMMEL`s innovative en-
the system also includes all the func-
engine compartment saving space
gine breathing technology for the air
tionality of air filtration and required
but not compromising the system’s
cleaner and both the dirty and clean
acoustic performance.
working capacity or servicing.
In this particular application the main
The air cleaner system is also equipped
One of the crucial design parameters
benefit is the optimum use of space:
with an automatic anti-snow system.
was the ability to provide an air cleaner
On one side of the air cleaner housing
At the bottom of the dirty side of the
Photo: © Fiat Chrysler Automobiles
Compact SUV – the new
Jeep Renegade
side ducts.
22
23
The intake manifold is produced for
the 2.5 liter gasoline engine (code
‘QR’) and is the first intake manifold
produced at the new production plant
of MANN+HUMMEL in Rayong, Thailand.
The air cleaner system for the 2.5 liter
diesel engine version (code ‘YD’) is
fully equipped with components from
Photo: © NISSAN
MANN+HUMMEL: A dirty air duct
with absorptive resonator, an air cleaner housing with air filter element, a
three-piece clean side duct and a high
pressure resonator. The upper and lower housing of the air cleaner are
connected via a hinge and clip
Nissan Navara – Midsize pickup truck in the fourth generation
connection for easy servicing. The
Air cleaner system for the Nissan Navara 2.5 liter gasoline engine
clean side duct consists of two injection molded rubber parts and a
The art of managing variants
3D blow molded middle section with
resistant PA6.6 GF35 and joining the
space requirements. Key to success
overmolded brackets and lambda-
injection molded shells by robust
was the high level of carry-over com-
quarter-tubes.
vibration welding with three additional
ponents. This is also true for an addi-
tie rods the resonator was made fit
tional diesel version (code ‘M9T’) with
for use.
slightly different power output.
Wide range of versions and tailor-made solutions for Nissan
As a supplier of global car manufacturers, MANN+HUMMEL is well aware of the increasing importance of leading edge technology appropriate to specific vehicles. Thereby MANN+HUMMEL sup-
The 2.5 liter gasoline en-
MANN+HUMMEL used its expertise
gine version (code ‘QR’) of
and competences with class leading
the air cleaner system
noise reduction measurements to
has a design reflec-
support the increasing focus of ve-
ting the different
hicle manufacturers on the acoustic
installation
improvement of their vehicles. 
ports its customers in achieving their objectives and overcoming challenges. At the same time,
MANN+HUMMEL is delivering solutions and systems globally, with class leading local engineering
support and production capability.
A significant case in point is the work
undertaken by MANN+HUMMEL for
its customer Nissan, involving the
highly popular Navara pickup truck,
High pressure resonator
withstands heavy conditions
also known by the name of Frontier
in the United States. The task of
MANN+HUMMEL was to develop intake manifolds for the gasoline en-
The high pressure resonator is an in-
gines as well as air cleaner systems
teresting part in respect of plastic en-
for both gasoline and diesel engines.
gineering. It has to perform in heavy
This involved engineering develop-
conditions with both high pressures
ment in Germany and Japan, resulting
and high temperatures. The surface-
in production ready systems for
to-volume ratio is quite challenging
MANN+HUMMEL manufacturing loca-
as the resonator had to be fitted in
the narrow space between engine and
tions in Spain, Thailand and Mexico.
Passive intake manifold for the Nissan Navara 2.5 liter gasoline engine
24
styling cover. Using high temperature
Air cleaner system for the Nissan Navara 2.5 liter diesel engine
25
At a glance
Fuel filter for the modular transverse matrix (MQB) of the
Volkswagen Group
With the new diesel fuel filter for the 1.6 and 2.0 liter diesel
Foto: © Adam Opel AG
engines, MANN+HUMMEL continues its success story as a
development partner and series supplier for the Volkswagen
Group. The fuel filter module with a replaceable filter element provides not only the current VW Golf VII with pure fuel
but also further models of the corporate brands Audi, Seat
and Škoda. The filter element utilizes the innovative fuel filter
medium MULTIGRADE F-MB 20, which represents the con-
New Opel Corsa with MANN+HUMMEL air cleaner
sistent enhancement of the successful MULTIGRADE F family.
MANN+HUMMEL IBÉRICA is exclusive supplier
With this filter media, smaller filter systems can be realized
compared to standard solutions with an unchanged service
interval and consistently good filtration efficiency. Thus,
In direct neighborhood to the Corsa plant of automobile manu-
MANN+HUMMEL offers its customers installation space
facturer Opel this air cleaner comes off the production line
benefits and contributes effectively to environmental protection thanks to reduced use of resources. 
in the Spanish Zaragoza at MANN+HUMMEL IBÉRICA. The
Diesel fuel filter with innovative fuel filter media MULTIGRADE F-MB 20
Spanish location is exclusive supplier for all air cleaners which
will be built into cars in the GM plant in Figueruelas. The compact air cleaner not only filters the air efficiently but also takes
care of the air intake noise. An extension (protrusion) of the
dirty air duct is fixed in the lower side via a plug-in connection
Top performance for Volkswagen – even under extreme conditions
to provide an improved acoustic as well as guiding the air flow
for an optimum distribution of the dirt particles on the filter
element. 
MANN+HUMMEL delivers air cleaners for different diesel and
Compact air cleaner from MANN+HUMMEL
gasoline engines which are built into e.g. the Volkswagen Sharan
and Audi Q3 models. To ensure the air supply of the engine even
under the toughest conditions the air cleaner can optionally be
New plat in Rayong, Thailand
equipped with a separated chamber in the lower housing with
secondary air opening. It is opened automatically at low temperatures and allows the engine to breath air free of snow.
Since 2014, MANN+HUMMEL has a production site in
A thermostatic element is actuating the cover flap.
Rayong, Thailand, in order to serve its customers of the
The pre-fleece at the filter element seals the separate
growing automotive industry. The plant is located at Hemaraj
chamber from the main air cleaner housing. Addi-
Eastern Seaboard Industrial Estate, right in the Thai automotive
tionally the air cleaner has a lamella grid which sepa-
industry cluster close to notable automobile manufacturers.
rates fine water droplets from the intake air. Addi-
Thereby, MANN+HUMMEL consistently expands its pro-
tional lamellas in the air cleaner wall in the dirty air
duction network in strategically important markets. Due to the
area contribute to the improved acoustic of the air
cleaner. The air cleaner is produced at the plant of
MANN+HUMMEL IBÉRICA in Zaragoza, Spain. 
new factory area of approximately 40,500 square-foot,
Cold country version: MANN+HUMMEL air cleaner
with automatic anti-snow-system
MANN+HUMMEL is now able to supply important regional
customers like Ford, Volvo, Nissan or Mazda. Main products
produced in Rayong are air cleaners, intake manifolds and
air ducts. 
26
MANN+HUMMEL production plant in Rayong
27
Compact
Globally customized solutions
The MANN+HUMMEL intake manifold offers not only
small installation space but also low weight, lower
CO2 emissions and high component cleanliness.
Cutting-edge engineering and manufacturing processes
are used to ensure that innovative products go successfully into production – professionally, reliably and globally
according to uniform standards.
www.mann-hummel.com