Transforming Loval’s Production with a New Automated Production Line
Loval Oy designs and manufactures advanced, customized tubular resistors, heating elements and solutions tailored to the unique needs of industries, including heat pump manufacturing, HORECA, laboratories, and various industrial applications. The products are made in Finland, and 95% of the production is exported worldwide.
The project in a nutshell
Challenge
To prepare for a significant increase in heat exchanger production volumes, Loval needed to improve efficiency and reduce manual handling. The company sought a modern, automated production line that would handle heavy lifting to improve worker safety and increase production speed and cost-efficiency.
Solutions and Services
Etteplan was selected to design and engineer the new automated heat exchanger production line. The project began by defining the customer’s challenges, followed by concept and solution definition process. To validate the feasibility of the concept, Etteplan created a 3D simulation of the entire line. Once the simulation‑validated solution was approved, the project moved into design and implementation, utilizing Etteplan’s mechanical, electrical, and automation expertise. The complete line was first assembled and test-run at Etteplan’s facilities, and after the successful testing, it was transferred to Loval, ramped up, and finally handed over to production.
Added value
The new automated line elevates Loval’s production efficiency, helps respond to growing market demand, and reduces physical strain on employees. The line is also designed to handle different product variants, ensuring flexibility and the ability to respond to different customer needs.
To prepare for a significant increase in heat exchanger production volumes, Loval needed to improve efficiency and reduce manual handling. The company sought a modern, automated production line that would handle heavy lifting to improve worker safety and increase production speed and cost-efficiency. This investment represented an important strategic step toward more modern and scalable production.
Etteplan turned manual manufacturing into an automated process
Etteplan was selected to design and engineer the new automated heat exchanger production line. The project began by defining the customer’s challenges, followed by concept and solution definition process to ensure a clear understanding of what needed to be solved.
"Etteplan has a strong reputation in the industry, demonstrated competence during the pre-engineering phase, and delivered solid proposals and technical solutions aligned with our needs."
Thomas Stendahl
Managing Director at Loval
To validate the feasibility of the concept, Etteplan created a 3D simulation of the entire line, placing equipment and processes in their intended positions. Once the simulation‑validated solution was approved, the project moved into design and implementation, utilizing Etteplan’s mechanical, electrical, and automation expertise.
The complete line was first assembled and test-run at Etteplan’s facilities. After successful testing, it was transferred to Loval, ramped up, and finally handed over to production.
”From challenge definition to commissioning, the customer was tightly involved. Our collaboration with Loval was productive, close, and smooth,” says Jari Luotonen, Director of Production Solutions at Etteplan.
Etteplan continues to support Loval after commissioning, providing maintenance services, updates, repairs, and system development.
“We continue supporting the customer after delivery with ongoing updates and improvements. We never leave the customer alone when a project ends,” Jari adds.
The new automated line elevates Loval’s production efficiency and helps respond to growing market demand
The automated line fundamentally transformed Loval’s production. Key benefits included:
- Significant efficiency gains: Automation now handles production steps that were previously done manually, resulting in a much more efficient process.
- Improved ergonomics: Heavy lifting is performed by machines, reducing physical strain on employees.
- Higher throughput: Loval can produce more cost-effectively and respond to growing market demand.
- Lower stock levels: Reduced work-in-progress has contributed to lower inventory costs.
The line is also designed to handle different product variants, ensuring flexibility and the ability to respond to different customer needs.
Thomas describes the cooperation with Etteplan as very positive, emphasizing close and open communication, strong local presence enabling quick on-site support, and the ability to deliver high-quality engineering work.
“I can recommend Etteplan to any production facility seeking to develop or build an automated production line."
Thomas Stendahl
Managing Director at Loval
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Director, EPS Finland