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The new panel line has resulted in a 35% increase in productivity and clear improvements in welding quality.
Challenge: The outdated production solution causes too much rework and low productivity.
Solution: High-productivity PEMA Membrane Wall Panel welding line with SAW process.
Benefit: Extremely high-quality panels with minimized deformation save time and money in production. Over 35% improvement in productivity.
The core of the line is the most advanced SAW welding technology enabling top quality for membrane wall panels.
Caldema Equipamentos Industriais Ltda., located in the city of Sertãozinho in the state of SP (Brazil), is one of the main boiler suppliers in Latin America. During its 47-year history, Caldema has systematically invested in the company’s technological development and strong financial results.
In addition to designing and manufacturing of boilers and boiler components, Caldema also manufactures hydrolysate machines, pressure vessels, and other equipment for third-party projects. Currently, Caldema has more than 350 boilers and supplied retrofits in operation.
As a part of the company’s future goal of becoming the world-leading boiler manufacturer, Caldema has made significant investments in order to improve its manufacturing productivity and quality.
One of Caldema’s latest investments has been the acquisition of PEMA 3000/6 – Membrane Wall Panel Welding Line. The new line was acquired to replace Caldema’s outdated and self-made tube panel welding solution with the MIG process because the process was unreliable causing too much rework and efficiency did not meet the expectations.
“Our productivity and welding quality was not high enough. This forced us to consider investing in new and more reliable technology,” described Leonardo Zanini, Director, Caldema Equipamentos Industriais.
“Delivery also included training, spare part packages, and installation supervision”
PEMA 3000/6 – Membrane Wall Panel Welding Line, based on advanced Lincoln Electric AC/DC SAW welding process, is a comprehensive welding solution that is designed for mass production of water tube panels. The line can weld panels up to the size of 3000mm x 26000mm.
In addition to the welding solution, delivery included also training, spare part packages, and installation supervision. Thanks to the flexible and modular design of the line, the solution can be built according to the customer’s production requirements. The custom-made design enables a further extension of production capacity at a later stage by adding the second stationary panel welding machine to the line. Additionally, the fast changeover time for tools makes the line flexible for different tubes and fin-bar sizes.
PEMA 3000/6 – Membrane Wall Panel Welding Line is equipped with userfriendly PEMA WeldControl 100 technology, which makes it possible to use minimal production staff when batch sizes are small.
“The panels are straight and the quality of welds is excellent which saves us time remarkably in the assembly phase of the boilers. Additionally, the rework of the welds has been minimized.”
Rubens Cherutim, one of the owners of Caldema, and his son Leonardo Zanini next to PEMA Membrane wall panel welding line.
Right after the launch of production with the new panel welding line, Caldema was able to see immediate benefits.
“The panels are straight and the quality of welds is excellent which saves us time remarkably in the assembly phase of the boilers. Additionally, rework of the welds has been minimized,” said Alexander Silva, Production Manager.
By investing in PEMA 3000/6 – Membrane Wall Panel Welding Line, Caldema has been able to reduce its production costs for membrane panels and consequently increase availability for new offerings.
“Thanks to its state-of-the-art technology, our panel manufacturing has had a considerable 35% improvement in productivity with an extremely low defect rate in the entire process,” summarizes Silva.
The capacity of the PEMA Membrane Wall Panel Welding Line can be further extended by adding a second stationary panel welding machine to the line.
For maximizing the output of the panel fabrication line, PEMA solution includes a fin-bar calibration line with a blasting process as well as an integrated tube and fin-bar in-feed system located next to the line. The tubes can be prepared and extended in the tube processing line, including tube OD-blasting process, tube end beveling and tube-to-tube welding system with integrated weld bead grinding feature and space provision for NDT.
To ensure fluent material handling on the panel fabrication line, the buffer storage system for sub-panels allows operators to have intermediate storage next to the line and feed the sub-panels to the welding station while minimizing the time used for crane handling.
PEMA Membrane Wall Panel Welding Line
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