Above: Davi’s MCE e-POWER allelectric plate roller is helping Aalberts improve part quality and achieve shorter lead times on its new in-house manufacturing line for Flamco mid-to-large steel tanks.
July, 2026- Hydronic HVAC systems serve as the foundational artery in building designs that provide energy efficiency, precise environmental control and reduced carbon impact. Aalberts hydronic flow control (hfc) in North America engineers and manufactures these missioncritical components for heating and cooling systems used n demanding environments.
Flat sheet is fed through the four-roll e-POWER to achieve a cylindrical shape before the longitudinal seam is welded.
Headquartered in Fishers, Indiana, Aalberts hfc NA operates as part of the Building segment of Dutch investment company Aalberts N.V. Originally the company’s Flamco products were designed and manufactured in Europe, but challenges with lead times and overall costs prompted Aalberts to bring production in house. The move laid the groundwork for the first automated U.S. manufacturing line for Flamco’s ASME-certified products, including expansion tanks and air and dirt separators.
To fabricate these products, Aalberts had to anchor the line with plate rolling equipment. It chose Davi Inc.’s MCE e-POWER; the all-electric plate rolling machine was installed in 2025. It eliminates hydraulic fluids and provides accuracy within 0.05 inches versus the 0.01 inch found in conventional plate rollers. The machine features Davi’s iRoll Performance CNC controller, which automates rolling parameters like speed, pressure and rolling angles.
FASTER CYCLE TIMES
“Investing in the e-POWER plate roller was an important step. It’s our only forming machine. We now have the tools to expand capacity and reach our goals for improving quality and achieving short lead times,” says Gavin Shipley, senior manufacturing engineer for Aalberts. “In addition to being quiet, the plate roller has 40 percent faster cycle times.”
The ability to roll steel into a continuous curve equips the vessel to safely manage expansion and contraction forces.
Shipley notes that the e-POWER plate roller’s efficiency is exceptional. “I’ve used other rollers in the past,” he continues. “The Davi e-POWER saves a significant amount of energy by consuming power only when it’s moving machine components.”
To fabricate the shells for Flamco’s expansion tanks and air and dirt separators, the process begins with a plasma-cut 5-foot by 10-foot sheet blank. The blank is fed through the four-roll e-POWER to achieve a cylindrical shape before the longitudinal seam is welded. Plate rolling allows the steel tank’s shell to withstand high internal pressures and maintain structural integrity and precise tolerances for welding. The ability to roll steel into a continuous curve also equips the vessel to safely manage expansion and contraction forces.
Plate rolling allows the steel tank’s shell to withstand high internal pressures and maintain structural integrity.
“Our Flamco Flextanks and Flamcovent Clean Smart separators are subjected to strict regulations such as the ASME Boiler and Pressure Vessel Code,” Shipley says. “North American customers expect the same stringent standards for products produced on our new line. It’s a rigorous six- to 12-month process that requires us to establish, document and implement a strict quality control system and undergo comprehensive audits by ASME and AIA [Authorized Inspection Agency].”
“We are in startup mode with programming for the overall line,” he continues. “This is a manufacturing line in a building that previously did not house fabrication. Programming for the e-POWER, on the other hand, has not required complicated programming. It is intuitive and easy to operate.
BUILDING CAPACITY
The plate roller’s CNC system has built-in artificial intelligence that automatically generates a program after the operator enters basic mate- rial specifications and part dimensions. The software uses historical parameters from similar parts while compensating for material inconsistencies in real time. Operators can also view real-time simulations of all bending and rolling phases before starting the process.
“Davi also provided training for our operators,” Shipley says. “Aalberts is looking to add personnel and ancillary equipment to support the operation. We are currently processing simpler parts—cutting, rolling and welding shells with fittings and ports. Our goal is to produce 8,000 units annually. The line has the capacity built in. We also have plans to bring our painting process in house.”
The Aalberts hfc NA headquarters houses administrative offices, manufacturing and distribution operations for its North American market. “We are already looking at expanding,” Shipley says. “It’s our commitment to the market to introduce innovative products” This new line is part of that, he says. “We have a lot of experience with traditional rolling. Now we are creating a new standard in lead time and quality.”
Aalberts hfc NA, 317/257-6050, aalberts-hfc.us
Davi Inc., 972/661-0288, davi.com
