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Aalberts Hydronic Flow Control and Davi

Aalberts Brings Steel Tank Shell Production In-House with Davi e-POWER Technology

Story overview

Aalberts Brings Steel Tank Shell Production In-House with Davi e-POWER Technology

Website

aalberts-hfc.us/

Location

USA

Industry

HVAC

Related products

MCE e-POWER , iRoll Performance

The Challenge

Aalberts previously relied on European manufacturing for its Flamco product line, leading to costly logistics and extended lead times for North American customers. To bring production in-house, the company had to set up an automated fabrication line in a facility that had not previously housed forming operations. The new setup required a forming machine capable of meeting strict ASME Boiler and Pressure Vessel Code standards, rolling plasma-cut blanks into uniform cylinders with tight tolerances for longitudinal seam welding, and ensuring fast, intuitive operation without complex programming barriers.

The Solution

Aalberts selected the Davi MCE e-POWER all-electric four-roll plate rolling machine as the central forming asset for its new manufacturing line. Controlled by the Davi iRoll Performance CNC with built-in AI, the system automatically calculates rolling programs from material specs and dimensions, runs real-time bending simulations, and compensates for material variations dynamically. Supported by comprehensive operator training from Davi, the all-electric machine replaced hydraulic systems, providing Aalberts with a quiet, energy-efficient, and highly repeatable forming process.

The Results

40% faster cycle times

compared to conventional rolling equipment, significantly accelerating shell throughput.

Superior energy efficiency and quiet operation

consuming electrical power only when moving machine components and eliminating hydraulic oil entirely.

Built-in capacity for 8,000 units annually

establishing shorter lead times and higher part quality across Flamco Flextanks and Flamcovent Clean Smart separator lines.

Streamlined job-shop workflow

CNC automation accelerates setup and changeover times, maximizing daily throughput on custom bending runs.

Headquartered in Fishers, Indiana, Aalberts hydronic flow control (hfc) North America—part of the Building segment of Dutch investment company Aalberts N.V.—engineers and manufactures mission-critical HVAC components, including Flamco ASME-certified expansion tanks and air and dirt separators. Originally designed and fabricated in Europe, these products faced long lead times and high overall logistics costs, prompting Aalberts to bring steel tank shell manufacturing in-house to the U.S.

To anchor its first automated U.S. production line, Aalberts invested in the Davi MCE e-POWER all-electric 4-roll plate roll, installed in 2025. Equipped with the iRoll Performance CNC, the machine delivers high rolling accuracy while eliminating hydraulic fluids entirely. Operating with 40% faster cycle times and drawing energy only when machine axes are moving, the Davi e-POWER enables Aalberts to meet strict ASME Boiler and Pressure Vessel Code standards and target an annual production volume of 8,000 units.