A complete tailor-made solution to meet Zehnder's goals

Filling Sealing Zehnder WEB-FIVES

Performance optimization of the heated towel rail production site at Vaux-Andigny, France.

Zehnder appointed Fives Filling & Sealing to optimize the filling process for its heated towel rail radiators facility in the North of France. The aim was to increase its capacity while improving filling quality, ensuring operator safety and improved ergonomics for its working stations. After successful results obtained from feasibility studies, Fives Filling & Sealing teams provided Zehnder with a bespoke pioneering filling process which ensured a high added value.

Zehnder is a European market leader in custom made radiators, heated and cooling ceilings and high-performance ventilation; its 3,500sqm assembly facility at Vaux Andigny, in the North of France, processes about 900 towel-rail radiator products per day, producing one radiator every minute

The filling process of this plant was unsuitable for the highly diversified product range being handled, and was the source of a high level of after-sale returns, often due to leakage or to performance issues. Spilt oil and slippery floors had an impact on operator safety. In addition, working conditions for operators had to be improved, in particular as regards the safe handling of tools and the ergonomics of the work stations. 

The Fives Filling & Sealing teams proposed a series of feasibility studies to Zehnder, for the purpose of acquiring a full understanding of the customer’s needs and constraints and in order to develop a specific process for degassing 60 liters of oil per minute. At the end of numerous tests and adjustments, Fives supplied the client with a first non-standard RapidCharge® machine comprising a French-made bearing-free pump which has never been previously installed on any other machine. 

Zehnder were very satisfied with this very innovative machine which met all of their requirements. The client therefore assigned Fives the task of optimizing its filling process, asking them for a second, and then a third RapidCharge® machine, developed using the same model.

Fives solution includes:

  • 3 RapidCharge® special filling machines
  • A sixty-liter-per-minute oil treatment station (degassing and temperature regulation)
  • Large volume storage for the treated oil (about 500 liters)

In 2015, Zehnder once again demonstrated its confidence in Fives during the installation of a new radiator line on its Manisa site in Turkey in 2015. Fives supplied the filling machines and carried out the testing.