Customer stories

Better productivity and safety for a steel wind tower manufacturer TEN

Torres Eólicas do Nordeste is a Brazilian company that specializes in the manufacturing of metal towers for wind power production. To the company, safety-at-work is a core value and one of the main reasons TEN has implemented PEMA solutions into their manufacturing processes since the establishment of their company. 

 

PEMA Heavy Duty (HD) series is designed for demanding welding automation purposes and enables high-quality production.

Torres Eólicas do Nordeste, TEN, is located near the main wind tower projects in the state of Bahia, within a region that covers over 80% of Brazil’s wind farms. The company was established in 2015, and its mission is to become a top steel tower manufacturer in Brazil. Pemamek has been a part of the company’s journey since the beginning, as TEN paid a visit to Pemamek’s premises in Loimaa, Finland already a year before opening their facilities.

“We have relied on Pemamek since the very early days: we paid a visit to Finland about a year before TEN was established. We were really satisfied with the solutions we saw and received our first order of PEMA solutions already in 2014 “, tells Mr. Roberto Padula, Manager of Operations at TEN.

CHALLENGE

TEN looks to decrease the amount of manual work and become a top steel tower manufacturer in the nation. 

SOLUTION

12 PEMA Assembly stations, integrated with six PEMA HD Column&Booms. PEMA Flange Fitting station. 

BENEFITS

Increase in productivity, less manual work, and highly improved safety-at-work. 

Reliable PEMA solutions since the early days

The first delivery from Pemamek included altogether 12 PEMA Assembly stations to guarantee flawless workpieces and excellent safety. The assembly stations are integrated with six PEMA Column&Booms, varying from PEMA HD 6×4 to PEMA HD 6×7,5. PEMA Heavy-Duty (HD) series is designed for demanding welding automation purposes and enables high-quality production.

“Our principles include more productivity, more safety, and less manual work. We found PEMA solutions to bring all these benefits to our manufacturing – investing in reliable solutions right from the beginning of our journey was important to us. With PEMA solutions, we have been able to automatize processes which results in better quality and productivity”, explains Padula.

TEN has trusted in PEMA solutions since the establishment of the company. 

“We highly value our close cooperation with Pemamek.

It is difficult to imagine what it would be like, to work without PEMA.”

  

Mr. Roberto Padula, Manager of Operations, TEN

PEMA Flange Fitting station improves both productivity and safety

Pleased with PEMA solutions and the cooperation, TEN decided to take another step towards better productivity in 2019 and invest in PEMA Flange Fitting station. PEMA Flange Fitting station (PEMA FF station) enables fast, safe and accurate fitting and welding of flanges to the wind tower and tower foundation sections. With PEMA FF station, flange fitting is possible without turning the shell, and cranes can be released to other tasks.

“Pemamek’s solution for handling flange fitting helps us to optimize the use of floor space and simplify our production. With PEMA Flange Fitting station, we have achieved significant reduction in process times and with this, our return on investment will be fast”, tells Mr. Carlos Konopatzki, General Manager at TEN.

In addition to better productivity, both Mr. Padula and Mr. Konopatzki emphasize the improvements in one of the company’s core values – safety. Having a safe working environment is a prominent concern for TEN as the company takes pride in meeting all strict safety requirements.

“Our productivity is faster, yet the most significant changes happened in the safety of our operations.” – Mr. Padula.

“With PEMA Flange Fitting station, the need for overhead cranes in minimized and moreover, the safety of the overall process improves – a benefit that we cannot put a price tag on.” – Mr. Konopatzki.

PEMA Flange Fitting station has helped TEN to optimize the use of floor space and simplify production.

PEMA solutions increase both productivity as well as safety-at-work.

“Pemamek is always ready and willing to help us”

Pemamek’s extensive knowledge and experience in the wind energy sector, combined with customized solutions, is the main reason behind TEN’s initial investments.

“In the wind energy sector, PEMA is a highly reliable partner. They have a lot of knowledge and they offer complete, modified solutions. With PEMA solutions, the amount of manual work in our manufacturing has decreased”, says Mr. Padula.

Mr. Padula describes the cooperation with Team PEMA as easy, fast, and assertive, and especially acknowledges the ease of adapting PEMA solutions into TEN’s production. According to Padula, TEN has never faced any difficulties with the implementation of PEMA equipment, and the start-up time has always been fast and effortless.

TEN takes pride in serving its customers with state-of-the-art equipment, meeting the requirements of safety and quality as well as the varying specifications of each customer project. For the modern and ambitious manufacturer of steel wind towers, close and reliable cooperation is irreplaceable.

“We highly value our close cooperation with Pemamek. They help us during the implementation process, answer any questions regarding PEMA equipment that we may have, and we also have regular visits and phone calls. They have always been ready and willing to help – it is difficult to imagine how it would be like, to work without PEMA”, finishes Mr. Padula.