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STULZ SPA

Our new factory

STULZ SPA, based in Verona, Northern Italy

We Got Bigger!

We are glad to announce the opening of our new production plant, officially presented during a ceremony held on the 27th of September 2016.

The new structure, next to the historical site of Valeggio sul Mincio (VR), covers over 9000 sqm, between stock (2500 sqm), offices (2000 sqm) and 4500 sqm for the new production lines. Why not check out our a short video that in less than 2 minutes will show you the construction and completion of this important project.

Raw Materials Warehouse

This warehouse is constantly supplied, with an average of entries which varies from 100 to 150 of raw materials pallets per day. As soon as a carrier approaches in the unloading area, the staff stores it where it is needed, according to the Just in Time logic.

Simultaneously, the warehouse staff, through a terminal, selects and unloads automatically the raw materials needed for the production and takes it to the production lines with a label which indicates the order number.

It is the responsibility of the production and of the supervisors, depending on the due date for the orders, to collect the raw materials and place it on the different working tables, one for each component of the units.

Production Department

Production is divided into three lines, industrial air conditioners, heat exchangers and telecommunication. The first 2 units consist of two automated lines each, plus a small manual line, while the telecommunication one is composed of two lines of roller conveyor.

Each line is composed of 7 workstations, one for the assembly, three for the cooling circuit, a 4th station for the filling of the refrigerant gas; a 5th for electrical, a 6th for testing and the last to close it. This process is the same for each machine, with operations described by us as “Time & Motion“; i.e. when the production of the units has similar timing, the advancement of the line is automatic. If a department requires different time phases between units, the line then has a manual feed of the roller assembly line.

Each workstation is equipped with a computer with a software, which allows operators to obtain information useful for the production, printing manuals and labels, to report problems, to request materials, to enter data and traceability and to enter information for testing.

Warehouse & Chiller Lines

Warehouse and Chiller Lines

Here we find the heart of our storage warehouse and the chiller lines, that are soon going to be completely moved to the new facility.

When there is no end date of shipment, the finished products from the higher level are moved here thanks to the freight elevator. The goods that are stored here which have to be shipped are lifted at the first floor, by the same freight elevator.

The chiller lines are the area of the production with the highest degree of customization and technical level. All the assembly lines are manual and we have an average output of 4/5 units per day. All the units produced here cool liquid, not air: this makes the process control of the temperatures much more efficient for our customers.

Prototype Area and Cell

Prototype area and cell

The highly specialized personnel working here realizes the project, verifying strong and weak points, proposing, with the technical office, useful solutions to improve the prototype. Once the prototype is completed, the unit goes to the cell department.

Typical types of tasks for of this laboratory include:

Capacity and efficiency testing of the unit
Test of temperature limits
Test of the unit for power outlets and tension for other countries
Noise test
IP Grade test
Safety test
Tuning test to validate new technical solutions
Validation of single components before large scale production
Cold Start and Hot Start tests from -40 to +60

New Warehouse

Back in January 2017 SAP software was implemented and the new warehouse had been chosen to test the new ERP.
The corridors of the warehouse are narrower than the others in the plant, in order to use all the surface. We have to use a high-efficiency forklift because of its narrow curving angle and lifting height of 8,5 m, compared to average forklift height of 5,5m.
We have a led lighting activated by motion sensors that guarantees energy savings; furthermore, we installed state-of-the-art shelving protections, that protects from impact trauma the operators of the forklifts.
A large number of gates is to ensure maximum flexibility in the supply of product ranges of raw material.

New Production

This zone shows how much the company cares about the quality of the work environment: all gasses have been centrally stored outside the building for maximum security, then transferred to each station via a distribution system; the work benches were designed and made adhoc for the best ergonomics possible. The new workstations include a trolley, support for label printers, hand tools, an adjustable support for production PC and a steel worktop that can be replaced to renew the working table.

Each line consists of 6 workstations: a test one and 5 tables, all identical to each other except the first two, that are twice the weight for more stable tightening operations.

For the placement of heavy raw materials, we opted for 200 kg, 500 kg and 1,000 kg hoists with a bracket that covers the whole production area and two overhead travelling cranes of 8 tons capacity each. With this, we can speed up both the assembly operations and the displacement of the larger units, for which we can use the two overhead travelling crane in tandem: double capacity with one remote control.

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