Germany's largest and most advanced toy production, storage and distribution facility
About 70% of the toys on sale in Germany are manufactured in the Far East. But the people at geobra Brandstätter GmbH & Co. KG – better known as the makers of PLAYMOBIL – are proud of their "Made in Europe" brand, producing toys in their own factories in Germany and Europe. The production site at Dietenhofen (district of Ansbach in Bavaria) is the heart of the manufacturing network. Since its launch in 1969 in over 250,000 square metres of its own land, the company has constantly expanded and invested, and now has roughly 110,000 square metres of enclosed production area. Approximately 1,200 people work here. Every day up to 10 million individual parts are made by more than 420 injection moulding machines, 250,000 parts are printed and an average of 65,000 PLAYMOBIL sets are packaged.
To meet the rising worldwide demand for PLAYMOBIL, a new injection mould shop with 80 machines and another fully-automated high-rack storage system with 12,000 storage positions were established in 2011. Both new building complexes went into operation in January and February 2012 and, according to Technical Director Robert Benker, have improved efficiency by 20%. Horst Brandstätter, the owner of the company, invested €25 million in these expansions, and he plans to invest a further €74.5 million in the production site in Germany during 2012.
The Brandstätter Group has another large, high-tech production site on the Mediterranean island of Malta which manufactures all the PLAYMOBIL figures – 2.5 billion since its market launch in 1974 – and the PLAYMOBIL 1.2.3 line for toddlers. A small facility is located in Spain, and in 2006 the assembly plant at Cheb (Czech Republic) began assembling and pre-packaging individual components in bags.
With successful certification under DIN EN ISO 14001:2009 in December 2011, geobra Brandstätter introduced a joint environmental management system for the PLAYMOBIL and LECHUZA brands. In combination with the company's environmental policy, this means the beginning of a process for the best possible protection of the environment and resources.
PLAYMOBIL Production at Dietenhofen Facts and Figures:
Overall area: 250,000 square metres
Enclosed production area: approximately 110,000 square metres
Number of pallet storage positions: 77,000
Number of injection moulding machines: 424, including 21 for the LECHUZA brand
Capacity of injected parts per day: up to 10 million
Average number of packages produced each day: 65,000
Number of employees in 2011 (annual average): 1,161
Consumption of plastic granules at Dietenhofen including contract injection moulders: 22,082 metric tonnes
Each day approximately 250,000 individual PLAYMOBIL parts are printed in the tampon printing process
DIN EN ISO 14001:2009 certification in 12/2011