Boiler manufacturing process
Production of central heating boilers
The production of a central heating boiler is a complex process that involves several steps and the use of various materials and technologies. Central heating boilers are essential devices for heat supply in households, industrial buildings and other structures. The boiler production process itself consists of formatting, dividing and bending flat steel sheets resistant to high temperatures and pressure on CNC equipment, preparation of other materials and parts, subsequent welding of boiler bodies under a protective atmosphere on modern welding machines and their pressure testing for water tightness, anti-corrosion surface treatment of boiler bodies as well as surface treatment of the casing with powder paint on a modern painting line, further assembly of the boiler and installation of all control electrical and electronic elements depending on the boiler equipment, installation of safety, control, operating elements and accessories, final comprehensive test with issuing of a final quality and complexity report of the boiler for each individual piece of product. The final phase is the final packaging of the boiler and its transfer to the shipping warehouse.
Boiler design, development and construction
The first step in the production cycle process is the design, development and construction of the boiler, taking into account the customer's needs, legislative regulations and EU technical standards. After approval of the design, development and construction take into account all requirements for achieving high utility value and quality of the boiler, maximum possible comfort of its use and efficient production with the aim of permanent user satisfaction. The design documentation of the prototype is prepared. This is followed by the production of the prototype, its internal testing and trials. After this, the drawing documentation and the guiding technology for the production process are completed. A verification series is produced, followed by so-called field tests of several pieces of boilers until the boiler is approved and approved for its inclusion in serial production with the preparation of the relevant documentation for the needs of a comprehensive production management system and documentation for operation and maintenance for customers as well as for installers and service technicians.
Laser and mechanical material cutting
The boiler production process begins with the cutting of high-quality sheet metal with a thickness of 3.5 and 6 mm. The most modern equipment is used for cutting the material, such as a punching center and a laser cutting center from Trumpf. These are German devices that are characterized by high quality. Thanks to the use of these devices, high accuracy is achieved in cutting the material. The laser cutting center allows you to process sheets up to 25 mm thick, and the punching machine up to 4 mm thick.
Manual and robotic sheet metal bending
The next step in the production process is the bending of the material. For bending smaller parts, manual part bending is used, while for large and heavier parts, robotic bending is used.
For bending, devices from Trumpf and Salvagnini are used, which work with high precision. The Salvagnini bending line allows bending sheets up to 3.2mm thick.
Boiler body welding, painting and pressure test
After preparing the required parts for the production of the boiler body, its actual welding takes place. Manual or robotic CNC welding is used for welding. The boiler body must first be assembled and connected using riveting, then the actual welding of the boiler body takes place. Welding machines from Fronius are used for welding.
After the welding of the boiler body, another important part of the production process comes, which is its actual pressure test. During the pressure test, the boiler body is pressurized to a pressure of 4.5 bar. The finished body is left under pressure twice for 4 hours. The final inspection confirms the tightness of the boiler body, and the pressure test performed in this way ensures the high quality of the boiler bodies.
After the pressure test, the boiler body is painted with environmentally friendly paint and sent for assembly.
Coating of the casing
The most modern powder coating line from Indufinish is used to paint the cladding parts, which meets the strictest criteria for environmental requirements such as paint application, paint recycling, etc., thus greatly saving our environment.
Assembly of the boiler to its final state and preparatin for shipment
After the production and preparation of all components necessary for the product, the boiler is completed. In the first phase, insulation is placed on the boiler to limit heat loss to the environment, insulation and door covers are installed, and the boiler is fitted with a casing. The boilers are fitted with LacFire refractory concrete combustion chambers. Subsequently, after the above components are installed, the electronic control, fan and other components are installed on the boiler. After the final inspection, the boiler is prepared for shipment and packed.
Quality and safety
The quality and safety of the boiler is a fundamental prerequisite for user satisfaction for us. Therefore, even during the production process, the compliance of the materials and technological processes used with the production and technical documentation is checked so that the boiler ensures long-term and reliable operation during use. The boiler is subjected to various tests and inspections to verify its quality and safety. These tests include tests for pressure, strength, tightness and other parameters to ensure that the boiler is able to withstand operating conditions and ensure reliable operation.
Ready-made boiler for you
Finally, once all technical and safety checks have been completed, the boiler is prepared for distribution and installation. The installers will install it into the domestic or commercial heating system and thoroughly test it to ensure it is functioning properly.
The entire process of manufacturing a central heating boiler is demanding and requires attention to detail and quality. Safety and reliability are key, which is why all steps in the production process are subject to thorough checks and tests to ensure optimal performance and a long life for the boiler.
Sales and service network
Boiler care does not end with their sale. We distribute boilers mainly through a sales network both in Slovakia and on the EU markets. In cooperation with our business partners, we have created a wide service network in individual regions, through which warranty and post-warranty service is provided. Our company also offers spare parts and selected accessories for boilers manufactured by us, even 20 years ago. As a rule, we can satisfy customers with spare parts for boilers that are more than 30 years old. The tradition of boiler production in our country dates back to 1965.