The new Flex factory in Zalaegerszeg demonstrates the strength of group-wide implementation

It is no coincidence that one of the world’s largest automotive suppliers, Flex—which has a presence in seven cities across Hungary—has built its new production facility in Zalaegerszeg. Over the years, ZalaZONE has become Europe’s most significant automotive development centre; as Flex, which manufactures components for more than 600 platforms across over 100 car brands, can thus maintain direct contact with its potential customers through its choice of location.

Flex is one of the world’s leading technology, manufacturing and supply chain service providers, employing nearly 140,000 people across more than 30 countries. They offer advanced manufacturing and supply chain solutions, innovative products and technology, and lifecycle services that support automotive, healthcare, industrial and electronics companies from concept to series production.

They are catering to the car manufacturing of the future

The company’s „next gen mobility” production unit is housed in the 8,000-square-metre high-cleanliness production hall of the 10,000-square-metre building. Here, high-voltage power conversion equipment for electric vehicles is manufactured on a fully automated production line using unique technology.

The scale of the project is clearly illustrated by a few key figures: the ventilation of the building, which is supported by 132 columns, is provided by 28 recirculation units and 12 ventilation units; for drainage, storage and fire-fighting water, the specialists had to install a 650 m³ sprinkler tank, a 1,599 m³ stormwater reservoir and a 150 m³ open-surface fire-fighting water reservoir.

All in one place

To overcome the key challenges facing the automotive industry, not only did the production facility have to be exceptional, but it also demanded precision and lightning-fast work from the contractor.

To address this, KÉSZ Csoport decided to implement the project primarily using the resources of its own member companies and strategic partners.

This allowed various units within the group to work on the building. The main construction work and the installation of the industrial flooring were carried out by KÉSZ Építő és Szerelő Zrt.; the steel structure installation, the installation of façade doors and windows (plastic and aluminium curtain walls) and the cladding works (complete roof structure and façade) were carried out by KÉSZ Metaltech; the steel structure was fabricated by KÉSZ Ipari Gyártó. DVB was also responsible for the prefabricated reinforced concrete structures, Provim for all electrical works, and MileStone Gazdasági és Mérnöki Kft. for health and safety and quality assurance. MA-HARD Kft. installed the fencing, Ventor Kft. carried out the full installation of the sprinkler system, and BAULOG handled the transport operations.

This is why Roland Horváth, project manager, emphasised the importance of this collaboration in response to our newspaper’s question:

 „This project is a perfect example of what true teamwork means. We worked to an extremely tight deadline and in phases, yet every discipline – from civil engineering through to mechanical and electrical works – performed excellently. I am proud of what we have achieved together: we have created a major, modern industrial facility that will shape the region’s industrial development in the long term.”

They had to hand over part of the building within seven months

The contractor took over the site on 3 July 2024, but by February 2025 had already handed over a 4,000 m² section of the building – complete with fully operational facilities and in possession of the necessary regulatory approvals.

The project required extremely disciplined organisation and weekly scheduling. In addition, particular attention had to be paid to the layout of the worksite to ensure that structural and façade works could proceed without disruption. During the winter period, heating the facility posed a particular challenge, as the installation of the industrial flooring and the execution of water-intensive technical processes (e.g. tiling, painting, etc.) fell within this period.

A bespoke technical solution

The factory also has a real treat in store for those familiar with the machinery:

One of the hall’s distinctive features is the secondary support structure designed by Hilti, which has been suspended from the beams using a non-destructive method known as ‘clamp fixing’. This supports the 8,000-square-metre suspended ceiling.

The combined walkway and equipment support structures, suspended from the purlins, were also constructed using a similarly innovative solution.

The specialists had to create a dust-free, positive-pressure production area, which required a specialised cleanroom approach in accordance with the ISO 8 classification (designed with a controlled humidification system operating at a positive pressure of 20 Pa).

It was necessary to get into a routine

It was not only the technology employed, but also the tight deadline, that justified entrusting the construction of the new production hall to a company that has repeatedly proven itself to be a reliable partner in investments by major automotive manufacturers and their associated suppliers.

For example, over the past few years, staff at KÉSZ Csoport have been working round the clock across nine different sites covering nearly 150,000 m² to ensure that Mercedes’ new production facility in Kecskemét could get up and running. The group has also established five vital units across 115,000 m² at BMW’s Debrecen plant complex; and for SMR Automotive Mirror Technology, they have carried out a total of 117,500 m² of factory development.

The benefits of a flat organisational structure have become apparent

The project was completed almost exactly one year after the site was handed over, which in itself is a clear illustration of the potential inherent in the group’s collaborative efforts; moreover, the factory was built to an exceptionally high standard. As those involved pointed out:

„KÉSZ Építő specialises in large-scale projects, as the Mercedes and BMW projects were similarly complex. The real strength of our group lies in the fact that we cover virtually the entire spectrum of construction activities, which, combined with the seamless cooperation of our member companies, led to the success of this project.”