ASM Industries, a part of the family-owned A. Silva Matos Group, is currently the largest wind tower manufacturer in Portugal.
With over 40 years of experience in the heavy manufacturing industry, ASM Industries operates in the field of manufacturing of steel equipment for renewable and marine industries, such as wind towers, offshore foundations and marine structures, with strategic locations in Portugal, serving the most demanded clients and partners in the global industry.
“We manufacture towers and foundations for the onshore and offshore wind energy industries. ASM Industries has two separate facilities, one in Sever do Vouga focusing on onshore towers, and Aveiro that concentrates on offshore wind tower and foundation manufacturing. In both facilities, we have PEMA production lines”, tells Ivo Goncalves.
The company’s abilities to produce high-quality wind towers have been also recognized among the industry key players, such as Energon, General Electric, and Siemens, to name a few.
“High quality and high performance are crucial for us. They are the foundation to build trust and long-lasting partnerships with our customers. That is why we find investing in modern technology so important”, describes Goncalves.
In 2016, the collaboration between ASM Industries and Pemamek got its initial kickstart. The company wanted to upgrade its onshore tower production machinery in Sever de Vouga to modern welding automation solutions.
“We began our first project with Pemamek in 2016 that was the production line investments for our onshore facility. This investment was important, as we needed to increase productivity in the facility.” Goncalves tells.
The final delivery included one PEMA Assembly station, three PEMA Column & Booms with SAW process, and ten sets of PEMA Roller beds.
During the past years, the investment in PEMA onshore tower production line has brought a significant jump in overall productivity. In the beginning, ASM Industries manufactured 8 sections in a week. Now, the number of manufactured sections is 12 per week.
“From the technical point of view, PEMA solutions were better than our previous machines. As an example, the assembly line had much broader features, such as self-alignment, which enables minimized distortion, better safety, and much faster process.” Goncalves continues. “We have made an impressive jump in our efficiency. In total, we have increased our manufacturing productivity by 40%.”
As a part of the company’s strategy and to meet future wind energy trends, ASM Industries made further investments also in its production machinery for offshore towers and foundations. This time, the destination of the delivery was on the coast of the Atlantic Ocean, in Aveiro.
“At the end of 2017, we bought two extensive PEMA offshore production lines to our Aveiro facilities. Everything included in the production line is from Pemamek. We purchased PEMA Column & Booms, roller beds, longitudinal and circular milling machines, and welding platform (WS2), among others.”
Even though some machines of the delivery were standard PEMA solutions, also customization and co-creation were involved during the process.
“To Aveiro facility, Pemamek provided a special technology that included a significant amount of new technology, such as laser seam tracking and semi-narrow gap technologies”, tells Goncalves.
Each of the processes of the production line was designed to guarantee fully optimized production. In case each process would be acquired from a separate supplier, the full productivity would have not been guaranteed.
“One of my favorite solutions is the WS2 welding platform which has two welding heads with anti-creep handling solutions. It makes the production also very safe, so we don’t need to worry that the work-piece would fall.”
In addition to smoothly running cooperation, Goncalves lists the benefits of acquiring all machinery from one supplier. According to Goncalves, this has brought much more flexibility and reliability to the entire project.
“It has been easy to collaborate with the PEMA people throughout the process. Our needs were understood right from the start. As a result, we have been able to trust the process, even though the overall project has been very extensive and large.”
Also, by investing in modern welding automation, ASM Industries has gained more digitality and intelligence into its offshore tower manufacturing.
“The development of the control interface is one the best advancements. It has streamlined the communication between the machine and the operator, but also, thanks to the extensive data collection, we have now a full understanding of the machines and operations”, summarizes Goncalves.
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