Boilers and heating systems
 July 9, 2024
Calusco D'Adda, Italy

Stargroup Tech for Caldaie Ravasio

At the beginning of 2024, the installation of an EvoBend 45 HD bending machine transformed the process of manufacturing the internal circuitry of Caldaie Ravasio's heat pumps.

Specialising for over 50 years in the construction of boilers and heating systems, the company from Calusco d'Adda (Italy) has recently extended its offer by designing and type-approving heat pumps that, combined with condensing boilers, form a state-of-the-art hybrid system.

The compelling need for a pipe bending system was felt in the production process of these heat pumps, which incorporate copper pipes varying in diameter from 16 to 64 millimetres and requiring an average of 25 bends per unit.

Caldaie Ravasio copper pipe circuitingAdded value from Stargroup

After an in-depth analysis of the technical specifications and requirements of Caldaie Ravasio, Stargroup proposed an EvoBend 45 HD bending machine, a special, customised version. This machine, with hybrid operation, integrates automated controls and hydraulic parts that ensure high performance at low cost. 

Such customisation allows bending of tubes with diameters larger than those normally machinable by an EvoBend 45, fully meeting customer requirements. 

Tangible benefits

The introduction of the EvoBend 45 HD changed the production cycle by drastically reducing the use of commercial bends welded to straight pipes, replacing them with a single pipe bent with the previous geometry and without any welding. The number of welds in the heat pumps dropped from 71 to just 27, reducing the risk of leaks by 62% and consequently improving product quality. 

The time savings also brought forward the production of a 50 kW pump by three days, cutting costs by 1.5%. In addition to these economic benefits, the safety of the products, which operate at high pressure, was significantly enhanced. In addition, the elimination of storage for pre-welded bends has freed up valuable space and further reduced operating costs.

In conclusion, production at Caldaie Ravasio doubled with the same number of operators and at the same time, effectively responding to growing market demand.