Titan Wind Energy’s strategic investment for offshore projects

Expanding XXL Offshore Wind Capacity: Titan Wind Energy Selects Davi for Four Heavy-Duty Rolling Lines

Story overview

With a passion for innovation and responsibility, as well as a firm commitment to dynamically shaping the energy infrastructure of the future, Titan Wind Energy (Germany) GmbH is your reliable German partner in the European wind industry – from idea to implementation. Join us as the power of the wind along the North Sea transforms into progress – with expertise and conviction.

Website

https://titan-wind.de/en/titan-wind-cuxhaven-monopile-manufacturing-for-offshore-wind/

Location

Germany

Industry

Wind Energy

Related products

MAV , MCB , CUSTOM AUTOMATED LINES

The Challenge

To support the global transition toward larger offshore wind turbines, wind tower and foundation manufacturers must scale up to fabricate "extra-large" (XXL) monopiles. These massive steel structures demand unprecedented plate thicknesses—often exceeding 100 mm (4 in.)—and wider plate dimensions to reduce the number of circumferential welds.

For global wind giants like Titan Wind Energy, setting up high-capacity production lines for XXL monopiles presents a complex operational challenge. Fabricating heavy, thick-walled cylindrical and conical cans requires massive bending power and precise control systems. Any deviation in roundness or tolerance during the rolling process leads to extensive manual rework, downstream welding misalignment, and costly production delays that threaten rigid project delivery schedules.

Furthermore, executing a multi-machine investment of this scale carries significant engineering risk. Fabricators need absolute certainty that the machinery will perform to exact specifications from day one.

The Solution

Four Custom, High-Capacity Rolling Lines

To mitigate these risks and secure Titan Wind Energy's manufacturing targets, Davi engineered and manufactured four heavy-duty plate rolling lines specifically customized for their XXL monopile production facilities.

This comprehensive technological package includes:

High-Capacity Davi MCB (4-Roll Plate Rolls): Built for high-volume repeatability and optimized pre-bending, ensuring fast, automated processing of thick steel plates.
Advanced Feeding and Material Handling Systems: Customized vertical and lateral guides to safely support, position, and rotate massive plates during the forming cycle.
Patented Servo-Tronic System: Davi’s dual, independent rolls parallelism control. By maintaining mechanical and hydraulic synchronization of the rolls, the system ensures consistent geometrical tolerances even in the event of an electronic failure, preventing unplanned downtime on the shop floor.
iRoll eXtreme Control Software & iCone Integration: An Industry 4.0-ready control platform combined with intelligent software to manage the positioning of pushers and hydro-guides automatically as the plate is continuously fed, facilitating precise conical rolling.

The Results

Drastic Cycle-Time Reduction

Automated plate handling, combined with the continuous feeding capabilities of the Davi Smart Line, accelerates the pre-bending and rolling steps, maximizing daily throughput.

Elimination of Material Waste

Unparalleled rolls clamping force and ideal torque transmission allow the plate to be positioned precisely at the tangent point. This delivers the shortest possible flat end, eliminating expensive test scrap and manual post-rolling correction.

Operator Safety

Advanced handling accessories and automated control software keep operators safely away from heavy, moving steel plates throughout the entire process.

Long-Term Asset Value

Every line is designed with compact, robust frames and easily sourceable, high-grade commercial components, simplifying maintenance and extending the useful life of the machinery.

The Industrial Credibility: Successful Factory Acceptance Tests (FAT) Completed on Schedule

This large-scale engineering project reached a major milestone at Davi’s headquarters in Cesena, Italy. Following rigorous quality and performance testing, Davi engineers, in close coordination with Titan Wind Energy's technical team, successfully completed the Factory Acceptance Tests (FAT) for all four heavy-duty plate rolls on schedule.

With all contractual performance metrics fully verified, the first of the four customized rolling lines is prepared for immediate shipment to Titan Wind Energy's facility, securing their project timeline and solidifying Davi's position as a trusted partner in the global offshore wind supply chain.