Driving Productivity & Stability at Bifrangi GmbH Austria
In today’s rapidly evolving manufacturing environment, long-term success depends not only on technological competitiveness but also on the strength of partnerships. OSG’s collaboration with Bifrangi GmbH Austria demonstrates how consistent technical support, shared problem‑solving and advanced tooling solutions can turn complex production challenges into measurable gains in efficiency, stability and product quality.
About Bifrangi GmbH Austria
Remaining competitive while upholding high standards of quality and safety is a primary focus for Bifrangi GmbH Austria, a subsidiary of the Bifrangi Group. The company’s history dates back to the 19th century in Mussolente, in the Venetian foothills—one of Northern Italy’s most dynamic industrial regions. Founded by Francesco Biasion, Bifrangi grew from a small craft‑based workshop into a technologically advanced manufacturing organization.
Since 2014, Bifrangi GmbH Austria has operated a modern 10,000‑square‑meter production facility, supported by a 5,000‑square‑meter underground area dedicated to chip treatment.
Hot steel forging has always been at the core of Bifrangi’s business, and over time the company has expanded its capabilities to include precision machining for automotive components, agricultural equipment, undercarriages for earthmoving machinery, flanges, pipe fittings and a wide range of industrial components.
Interior view of Bifrangi’s Althofen plant in Carinthia, Austria.
Since 2014, Bifrangi GmbH Austria has operated a modern 10,000‑square‑meter production facility, supported by an additional 5,000‑square‑meter underground area dedicated to chip treatment. The site employs roughly 70 people. Its continuous commitment to energy efficiency, environmental sustainability and high product quality has made Bifrangi a trusted partner for major industrial companies throughout Europe and the United States. Today, the company produces more than 2,000 items ranging from 0.3 to 150 kilograms, with thousands of machined components shipped worldwide each day. At its Althofen plant in Carinthia, Austria, Bifrangi manages every stage of production—from forged blanks to finished components—supported by an extensive, modern machine park.
Driving Improvement Through Collaboration
Bifrangi aimed to increase productivity, extend tool life, stabilize tapping processes and improve chip control in two high‑volume carbon steel applications. Through close collaboration between Bifrangi’s engineering team and OSG’s technical specialists, and by implementing OSG’s VI‑HS‑POT tapping solutions, the company achieved substantial improvements across all objectives.
OSG’s VI‑HS‑POT tap is engineered for high‑strength materials and demanding production cycles.
Application 1: Wheel Hub (C50 Carbon Steel)
The first component analyzed was a C50 steel wheel hub produced since 2016 at an annual volume of approximately 1.2 million pieces. Manufactured in batches of 200,000 and processed continuously over three eight‑hour shifts, the part requires four M12×1.5 threaded through‑holes at a depth of 14 mm. A material change introduced to meet new environmental regulations resulted in issues with chip evacuation and tapping stability.
Wheel hub made of C50 carbon steel. Each part requires four M12×1.5 threaded through‑holes at a depth of 14 mm.
To address these concerns, OSG recommended the custom VI‑HS‑POT tap (EDP: T2511948), engineered for high‑strength materials and demanding production cycles. The tool delivered immediate and significant benefits. Tool life increased from 1,600 to 2,400 threads, a 50 percent improvement over the previous solution. Thread surface quality improved noticeably, and chip evacuation issues were fully resolved, resulting in greater process stability and reduced machine downtime. Cutting conditions included a speed of 20 m/min, a rotational speed of 530 rpm and a feed rate of 795 mm/min. A 10.5 mm pre‑hole, produced using a high‑quality step drill, ensured compatibility and consistency in the tapping process.
A C50 carbon steel wheel hub threaded using OSG’s VI‑HS‑POT tap.
Application 2: Wheel Hub (C56 Carbon Steel)
The second component analyzed was a C56 steel wheel hub for commercial vehicles, produced annually since 2016 at a rate of roughly 250,000 pieces in batches of 50,000. Each part requires five M14×1.5 through‑holes at a depth of 16 mm. Machining takes place on two separate lines, each presenting its own difficulties. One line faced tapping instability caused by material changes, while the second struggled with chip evacuation due to the clamping configuration.
Wheel hubs made of C56 carbon steel. Each part includes five M14×1.5 through‑holes with a depth of 16 mm.
For both lines, OSG introduced the custom VI‑HS‑POT M14×1.5 tap (EDP: T2511153), chosen for its ability to maintain reliable chip control and long tool life. On Line 1, operated on an EMAG VL4 machine, the cutting parameters included a 25 m/min cutting speed, 50 m/min return speed, a forward rotational speed of 570 rpm, a reverse speed of 1,140 rpm and feeds of 855 mm/min forward and 1,710 mm/min reverse. Under these conditions, tool life increased from 1,500 to 3,075 threads, an improvement of 105 percent compared with the previously used tap.
A fleet of EMAG VL4 vertical turning machines at Bifrangi’s Althofen plant in Carinthia, Austria.
Line 2, running on a Vigel 325 TH machining center, required adapted conditions: a cutting speed of 30 m/min, a return speed of 60 m/min, a forward rotational speed of 680 rpm, a reverse speed of 1,360 rpm and feeds of 1,020 mm/min forward and 2,040 mm/min reverse. With cutting conditions unchanged, the new tool geometry increased tool life from 2,125 to 2,530 threads—a 19 percent gain—and completely eliminated chip‑evacuation issues. Both lines used a 12.5 mm pre‑hole produced with a step drill that ensured consistent hole quality and smooth integration with the tapping process.
A C56 carbon steel wheel hub threaded using OSG’s VI‑HS‑POT tap.
The Human Element Behind the Success
The results achieved in these applications were not driven solely by advanced tooling, but by the collaboration and trust built throughout the partnership. Bifrangi Italia and Bifrangi GmbH Austria first engaged with OSG through area representative Alberto Pasquali, whose commitment extended beyond commercial activity and fostered a strong professional relationship—particularly with company owner Roberto Biasion and purchasing manager Fabio Pegoraro. This foundation of trust supported a shared, long‑term approach to refining and improving manufacturing processes.
From left, OSG Italia engineering manager Andrea Severi and Bifrangi GmbH production manager Francesco Mocellin pose for a photograph at Bifrangi’s Althofen plant in Carinthia, Austria.
OSG Italia Engineering Manager Andrea Severi further strengthened the partnership by providing on‑site technical expertise, optimizing cutting parameters and monitoring performance throughout the implementation. His contributions helped validate the tooling solutions and ensured their seamless integration into Bifrangi’s production environment.
Conclusion: A Partnership Built on Trust and Performance
The applications analyzed show how strong collaboration and innovative tooling can transform production challenges into opportunities for improvement. In every case, the introduction of the VI‑HS‑POT tap enhanced tool life, improved thread quality and increased machining reliability, even as materials and production requirements evolved. The partnership between Bifrangi and OSG stands as a clear example of how technology, expertise and human relationships—working together toward shared goals—can generate long‑lasting, mutually beneficial success.
For more information on OSG’s tap offering, OSG Italia, and Bifrangi
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