In the ovens for bakers manufacturing, the use of high quality materials and an efficient production process assure complete customer satisfaction. (video: SALVA)
Ovens for bakers and cake makers with more than 75 years behind it, Salva Industrial develops professional solutions looking for top quality equipment, unwilling to compromise on performance or waive control over their businesses. And in its manufacturing process, the Gipuzkoa-based company leads by example: an MV automatic tray-store by Salvagnini is the cornerstone of a fully-automated factory with fully-integrated logistics, from the design of the equipment through to the delivery of the product to the customer.
A point of reference in the manufacture of ovens for bakers and caterers
SALVA’s manufacturing base boasts impressive installations that cover around 20,000 square meters. With a total workforce of 270, 165 of whom work at this plant in Lezo (Gipuzkoa), it is here that all the group’s stainless steel is processed.
SALVA’s annual turnover exceeds 30 million euros, of which export accounts for more than 60 percent. The company is now an established international point of reference in the manufacture of top-of-the-range ovens for bakers and caterers: modular ovens, convection ovens, rotary ovens, cyclothermic ovens, electric deck ovens and annular tube ovens.
High quality in materials with efficient production for customer satisfaction
And this just goes to prove the quality, reliability and hard-wearing design of this equipment: 80 percent of ovens for bakers sold by the company in the last 20 years, continue to work today. SALVA subjects its ovens to demanding tests, pushing them right to the limit to guarantee that even the most demanding market conditions are met.
Use of high quality materials and an efficient production process assure complete customer satisfaction.
Designs go well beyond a mere sleek look, achieving top performance in terms of safety, durability, productivity, ease of use and simplicity.
More than just a supplier
“The quality of the end product is our business card when we introduce ourselves to a customer,” confirms David Llordés, General Manager of SALVA and the third generation of this family business. “And this quality is the result not only of our use of the very best materials in manufacturing, but also the efficiency of the production process,” he adds.
To achieve this objective, SALVA has for decades now chosen to rely on the sheet metal processing equipment offered by the Italian manufacturer, Salvagnini.
“We see Salvagnini as a partner, rather than just a supplier of machines and systems. The collaboration between our two companies has enabled us to optimize production and obtain guarantees in the workflows necessary to achieve our goals. We collaborate with Salvagnini to analyze our needs; we advise each other, each applying their own know-how and adapting it to suit SALVA. This is what we have done for each and every one of the solutions installed in the factory,” adds Mr Llordés.
Salvagnini solutions for all the sheet metal flows for each process
SALVA has spent more than 15 years getting maximum performance out of the Salvagnini MV automatic tray-store, the real cornerstone of the company’s sheet metal forming and shearing process.
This solution allows for the real-time coordination and transfer of all the sheet metal flows needed for each process (laser cutting, punching, shearing and panel bending), cutting costs and reducing wait time, while increasing the factory’s overall efficiency.
Thanks to the Salvagnini software, the material to be processed flows automatically from cutting to bending in a fully integrated production process.
“Although at first sight, its size makes it look like a less flexible system than traditional loading and unloading systems, this could not be further from the truth. We are firmly convinced that this is the best solution for what we need. It is perfect for us. The wide range of ovens we manufacture leads us to work with a great variety of metal sheet, which may need to be laser cut, punched, sheared or bent. This system allows us to access the sheet metal immediately and release it when necessary,” SALVA’s General Manager explains. “The productivity and flexibility of this system are shown day-in, day-out in the factory and accompany the entire production process. At present, it runs for 24 hours a day, 5 days a week, so reliability needs to be top class too,” he adds.
SALVA MV automatic tray store connected to S4 punching machine, P4 panel bender and L5 fiber laser
SALVA scrupulously monitors its Salvagnini installation, the workshop’s production heart. It does so by applying a complete and easy-to-follow maintenance program. “System activity has been frenetic for years. It is a highly reliable installation and we do everything within our power to make sure this continues to be the case. And in this regard, correct maintenance is essential if we are to avoid downtime,” David Llordés points out.
The SALVA MV automatic tray-store, controlled from the technical office, is connected to three Salvagnini machines: an S4 punching machine and a P4 panel bender – installed in 2003 – and an L5 fiber laser, which has been with the company since 2016. Unlike other equipment also supplied by the Italian brand (for example, the well-known S4+P4 combination), they do not operate in line, but separately.
Maximum efficiency: standard machines with customized connection for SALVA
“The unique aspects effectively required of our manufacturing process mean that this distribution of machines allows us to achieve maximum efficiency. They are standard machines with a customized connection for SALVA. The raw materials – and, in particular, the stainless steel – are not exactly cheap and this layout of equipment allows us to make best use of the material. Additionally, with the different formats with which we work, what often occurs is that sheet metal requires laser cutting, punching or shearing before then moving on to panel bending. With this configuration, idle time in the process is kept to a minimum,” David Llordés explains.
Adaptive fiber laser with high dynamics
The latest machine installed by Salvagnini in the Gipuzkoa-based oven manufacturer’s factory was an L5 fiber laser.
Although it is perhaps a brand better known worldwide on the panel bender machine market, Salvagnini was also a pioneer in investing in fiber technology.
The L5 is a productive, versatile solution with high dynamics and reduced operating costs, as well as being environmentally friendly. In Salvagnini laser systems, the laser beam is generated and conveyed by fiber.
The beam is generated by means of an electronic source, while it is conveyed by standard fiber, which does not require an optic trajectory. This translates into reduced consumption, thanks to the high performance of the source (40%), and a drastic reduction in maintenance and consumable costs.
Three adjustable cutting functions: Standard, PowerCut and DynamicCut
The L5 systems include a head with a single optic that offers a high quality cut over the whole range of thicknesses.
SALVA works with fairly thin sheet metal, up to 2 mm thick, assuring rapid production changes and eliminating set-up time.
The patented Dry Cooling technology cools the optics without any supply of gas or fluids, enabling active lens temperature control.
The L5 is equipped the three adjustable cutting functions: Standard, PowerCut and DynamicCut, allowing for the choice of the most suitable operating mode for the different production needs; they can be activated easily, by means of a activator.
Standard mode guarantees greater safety during unmanned production, whilst PowerCut mode offers reactivity and greater speed of execution.
DynamicCut enables better performance in medium-fine thicknesses, making the most of the machine dynamics.
A clear future on ovens for bakers: 4.0 technology working hard to become a point of recerence in the sector
The export portion of 60 percent mentioned previously includes a hundred or so countries where SALVA markets its prestigious ovens, with France and Australia, along with regions like the Middle East or South East Asia, standing out in terms of volumes.
Over the next few years, the company hopes to increase its ovens for bakers sales internationally, improving management of its distribution network and strengthening its commercial action in the countries it holds to be strategic, like the United States. It will also work hard to become a point of reference in the sector for the installation of 4.0 technologies on its equipment.
A couple of years ago, SALVA set up a showroom in its central offices in Lezo, specifically for customers. This included a Test Bakery, where bakery courses were delivered, and a sample of many of the ovens manufactured by the company.
“In addition to seeing the showroom, the customers also want to visit the factory,” David Llordés concludes. This means that customers approaching the showroom are always welcome and invited to pop into the factory, which the company is proud to show off and where the spectacular installation supplied by Salvagnini leaves no one indifferent.
The customer can see for himself: the secret does not always lie in the dough. In SALVA, at the start and end of the process, quality leads the way.
(credits: Iván González – Revista Tope https://www.revistatope.com/)