E N T E R I N G Y O U R W O R L D

We strive to be a reference, not just a name

1971Up on the hills about 70 km

north-east of Lyons Paul Malerba

and Jean-Jacques Dugelet started

their metal-door-frame company,

in Cours-la-Ville.

1982The firm diversified for the first time,

going into metal door units for

joiners working on housing projects.

1989The start of wooden-door making,

for external expansion.

1997The range was diversified again,

with the Technical Metal Doors (TMD)

range, designed for metal

locksmiths.

2005Bruno Malerba took over from his

father.

2009Takeover of Menou, a firm

specialized in standard wooden

door units for the professional trade

and DIY outlets.

2010Reorganization of the Technical

Support Unit, and the Specifying

Department.

2011Incorporation of Montibert,

a company specialized in indoor

fire-door solutions.

2012Expansion of MD into M-Center

distribution points, veritable relays

between factories for professionals.

AN INNOVATIVE APPROACH TO PRODUCTS

Heat, acoustic, fire and theft resistance, plus flood

protection… our door unit performances are constantly

being improved. To achieve that our Design Office has a

testing laboratory where potential new solutions worked

out with our clients are assessed upstream. Our aim is to

provide the best door units, ones that respond to today’s

building industry challenges.

ALWAYS BY YOUR SIDETo provide backing for our two sales

networks we have implemented a

Technical Support Unit dedicated to major

projects and studies of complex items.

Our intention is to play a very active role

in building matters by contributing —from

the drawing board—technical support that

enhances the overall quality

of end results.

> Steel sheets 12,600 tonnes p.a.

> Surface painting 37 tonnes p.a.

> Primary coats 102 tonnes p.a.

> Wood-fibre panels 3,790,000 m2 p.a. [936 acres!]

> Official fire-resistance reports awarded more than 250

MALERBA, SOME KEY FIGURES

In just two generations our company has become

a national benchmark in terms of doors for the

housing, tertiary, hospital and industry sectors.

To meet the growing demands of our clients—while

dealing with the varied applications of our products

—we have developed a unique industrial tool.

We have over 100,000 m2—nearly 25 acres, or a million square feet—of factories, storage areas and offices

around Cours-la-Ville where we began. To ensure maximum reactivity each unit has leading-edge technology

to guarantee flawless production, and meets the highest standards of quality and precision.

Also… to respond to building industry demands we have two thoroughly tried and tested logistics partners

specialized in delivering our products to building sites.

MADE IN FRANCE Our products are all made to order to meet the specific needs of each architectural project. To ensure the best

delivery times while strictly complying with prevailing building standards we have chosen to maintain our entire

production operation in France. This local approach between our various units means that we can combine

and share the high-level skills and know-how of all our operators.

A NOVEL INDUSTRIAL APPROACH

Coil splitting in Factory 2

CERTAINTY BEYOND STANDARDS To demonstrate compliance with

the standards and quality of our

products, we are committed to

numerous certifications in

partnership with the most reputable

organizations. We refuse all

compromise in matters of quality

and we guarantee each of our door

units. Our monitoring of regulations

goes hand in hand with our desire

to participate actively in the

development of good practices

in building sectors.

NF = Norme Française, the equivalent of BS, or ASA FASTE = Fire, Acoustics, Stability, Thermal, [forced]Entry

Our trademark is above all

our reputation

MAKING INNOVATIONS AVAILABLE Malerba products are on display in three show-rooms—two in Cours-la-Ville and one just outside Paris—that are also venues for technical exchanges and training sessions.

MARQUAGE

PORTE EXTÉRIE

URE

Fire-resistant doors

FASTE-rated indoor

door units

Door units

EVER BETTER CONTACTS WITH PROFESSIONALS In order to better respond to demands, we have

organized our sales networks into areas of

expertise. Carpenters and joiners, locksmiths

and metal-workers, general contractors, but also

designers and contracting authorities—they all

have access to regional support and help, from

the drawing board through to the reception of

programmes. These help-providers rely on the

skills of the Design Office personnel, together

with the Technical Support Unit to ensure

the best harmony between needs and products.

Our company is located in some beautiful surroundings where we have always sought to respect the environment. Our present sustainable development policy comes to life in practical terms through all the elements of our organization.

Products: each product line has a data-sheet spelling out its environmental impact.

Certification: we hold both PEFC and FSC certificates, for our procurements and and the production of our wooden door units.

Regulations: when the ATF-BTP* professional association was created as part of the FIBC (Federation de l’Industrie Bois Construction), we became involved in many standards and regulatory issues. In particular we work on the creation of joint schemes so as to draw up Environmental Product Declaration (DEP) sheets common to manufacturers of wooden door units, whether solid or with windows, or glazed frames.

Infrastructures: all our facilities meet the most stringent requirements and standards. To improve the environmental results of our activities we have multiplied our initiatives:• our wood factories are equipped with heating equipment

to recycle the chips generated in manufacturing,• energy-saving steps in the production units—

high-performance machines are chosen, with variable speed systems, etc,

• water consumption and pollutant discharges reduced (cutting water consumption by 50% in less than ten years),

• VOC (Volatile Organic Compounds) down by 90% after modifying painting procedures between 2001 and 2008,

• recycling and optimizing raw materials, value-adding 70% of our factory waste,

Lastly, thanks to a roof we have installed covered with photovoltaic cells we are also producers of 110,000 kilowatts of solar electricity per year.

*Technical Association of Technical Door Manufacturers

A PROACTIVE ENVIRONMENTAL APPROACH

10-31-2004

Cette entreprisea fait certifier sa

chaîne de contrôle.pefc-france.org

Avec vous, Malerba s’e

ngage durablement

L e s e n s de l ’ o u ve r t u re

3 vilets horizontal DevDur:Mise en page 1 18/03/10 17:05 Page 2

Every Malerba door unit has an Environmental Product File Report

The life cycles of all the types of Malerba products—wooden doors, metal door units, Technical Metal Doors, and frames—have been analysed. These studies have enabled quantified diagnoses to be made of the environmental impacts

of our ranges of products—energy consumption, CO2 emissions, water consumption, air pollution, water pollution, etc.

These data, recorded on Environmental Product File Reports (FPBE), are used to validate the suitability of our products with sustainable construction projects (HQE®, BBC, RT2012, etc.).

Fiche Produit Bilan Environnemental

1 - Fabricant

2 - Site de fabrication

3 - Gamme de produit

4 - Description du produit

5 - Fonction

6 - Performances techniques

7 - Entretien / Maintenance

8 - Unité fonctionnelle

9 - Durée de vie typique

PEFC: This company has had its control line certified. FSC: The mark of the Forest Stewardship Council

Met

al d

oor f

ram

es

Metal door frames are what have really built the reputation

of our business. Whether made by profiling or by folding,

their standard manufacture includes high-performance

anti-corrosion treatment. They are available pre-painted

or with a lacquer finish, but always Malerba-signed quality.

Find out more about our most recent products

P11P10

Speciality: Metal door frames

Built in 1971

Area: 10,000 m2 (2.47 acres)

Output capacity: 2,500 door frames per day

Split coils

One of the profiling lines

Spot-welding the accessories

One of the plate-bending presses

Welding robot

Manual mounting workstation

Fitting accessories on the line

Anti-corrosion treatment by dipping

Removal from the oven prior to dispatchingP13P12

Factory4

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Met

al d

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nits

fo

r Hou

sing

Our metal door units are the best guarantee of

safety and comfort. Long admired for their

technical qualities, they are now also available with

novel finishes in tune with current building trends.

P15P14

Find out more about our most recent products

Stock of coated metal sheets

Sheet metal punching

One of the plate-bending presses

Core bonding

Fitting plugs, pegs and locks

The finishing touches—the oculi and the mouldings

One of the ‘hook and toggle’ workstations

Pre-packing and pre-dispatch storageP17P16

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Speciality: Metal door units for housing

Built in 1982

Area: 10,000 m2 (2.47 acres)

Output capacity: 550 units per day

3

Stock of coated metal sheets Sheet metal punching 21

4 7Factory

Whether in new or renovated buildings our wooden door

units blend in with all indoor and outdoor schemes. Their

success is like their composition: sustainable.

P19P18

Woo

den

doo

r uni

ts

for h

ousi

ng

Find out more about our most recent products

Work also involves sharing space and facilities. Our door

units contribute to harmony in shared spaces, while

maintaining the comfort of each person, and guaranteeing

compliance with all building standards.

P21P20

Terti

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sect

or

woo

den

door

uni

ts:

Offi

ces,

Edu

catio

n, H

otel

s, C

ultu

re

Find out more about our most recent products

Here, strictness is the rule: emergency, silence, performance?

Our doors match patient and care-giver expectations directly.

P23P22

Terti

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sect

or

woo

den

door

uni

ts:

Hea

lth a

nd H

ospi

tal

Find out more about our most recent products

P25P24

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Steaming and stabilizing the wood

Composition robots for anti-break-in and acoustic cores

Composition of solid laminated cores

One of our machining workstations

Machining, closeup

Intermediate storage, prior to finishing

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Speciality: Wooden door units for housing

and the Tertiary Sector.

Built in 1989

Area: 24,000 m2 (5.93 acres)

Output capacity: 3,000 leaves per day1

Composite robots for the anti-break-in and acoustic cores 2

Factory

P27P26

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Positioning thermo-inflating joints and built-in accessories

Turning over to position the cover strips and the oculi

Placing the oculi

Placing pins and plugs

Monitoring traceability of orders in the factory

Checking the laminated leaves before packing

Checking the laminated leaves before dispatching

Tracking-labels for unit upgrading

Dispatching orders

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Positioning thermo-inflating joints and built-in accessories Dispatching orders 15

14

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Factory

Part of the facilities

Storage of raw materials

Delignification

Production monitoring

Assembling door units prior to pressing

Robot distribution

‘Hook and toggle’

Assembling the frames

View of the assembly line

Storage of raw materials

Delignification

Packing and dispatching

P29P28

WO

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Factory

Speciality: Wooden door frames

Built in 2006

Area: 10,000 m2 (2.47 acres)

Output capacity: 500 door frames per day

Speciality: Wooden door frames and units for the trade.

Built in 2012

Area: 12,000 m2 (2.97 acres)

Output capacity: 2,000 door units per day

Factory

Our Technical Metal Doors are at home in all types of industrial

environments: they have many optional features and technologies

that can be adapted to all your requirements.

P31P30

Tech

nica

l Met

al D

oors

Find out more about our most recent products

Punching

Folding by press

Manual welding of frames

Painting

Epoxy-cooking oven

Core fitting

Fastening accessories

Installing pivots

Quality Control

Packing

Pre-dispatch storage area

P33P32

DO

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Factory

Speciality: Door units and Technical Metal Doors

Built in 1997

Area: 9,600 m2 (2.37 acres)

Output capacity: 135 panels per day

3

2

Sheet metal cutting

Automatic sheet-metal punching

Assembly line

Fastening accessories

Fastening the split hinges

Quality Control

P35P34

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6 Automatic sheet-metal punching 2

Factory

Speciality: Door units for emergency

and service exits

Built in 2010

Area: 6,000 m2 (1.48 acres)

Output capacity: 100 door units per day

Vitre

ous

prod

ucts

, ha

tche

s &

she

ath

faca

des

Montibert—a company specialized in fire-door solutions

inside buildings—is now part of the Malerba range on offer.

Developed in synergy, the Malerba and Montibert products

perfectly complement and enrich each other while conforming

with the strictest standards.

P37P36

Find out more about our most recent products

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Storage of raw materials

PEFC-certified wood

Overview

Order scheduling office

Delignification

Flow

Assembly workshop

Installing the glass

Closeup of finish P39P38

Montibert

VI

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Installing the glass Closeup of finish 109

1

Speciality: indoor fire-door solutions

Built in 2012

Area: 7,700 m2 (1.9 acres)

Output capacity: 130 fire-door products per day

www.malerba.fr Rue Paul Malerba - 69470 Cours-la-Ville Tel.: +33 (0) 4 7489 8585 - Fax: +33 (0) 4 7489 8257 - info@malerba.fr

Des

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the

inte

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Jan

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