Fhiaba | Combined Technologies for Luxury Refrigeration

The refrigeration industry has undergone a significant transformation over time. Once viewed as a mere household convenience, refrigeration has evolved into a coveted status symbol that attracts and retains a growing customer base. Food preservation appliances such as refrigerators, freezers, blast chillers and small wine cellars have become a prominent feature in the kitchen. The design, technology and performance of these appliances have converged to offer unique functional experiences. Fhiaba has a long and significant commitment to this industry and is a leader in the production of high quality equipment. "The company," explains CEO, Massimo Baron Toaldo, "was founded in 2004 by my father, Cavalier Antonio Baron Toaldo, after a long career in the commercial refrigerator manufacturing sector. This legacy has resulted in a global presence in the most demanding markets, including North America, Australia, Europe, and China. "The distinctive quality of Fhiaba" states Baron Toaldo "lies in its unique ability to integrate industrial production with Italian ingenuity, a result of decades of expertise in steel processing. Another key strength is the company's relatively small size compared to its international competitors. Despite this, it is able to maintain high production levels and offer significant operational flexibility." These prerogatives have enabled Fhiaba to establish itself in the high-end market, offering innovative, tailor-made solutions that combine high performance and refined design. The success of these results is largely attributable to Prima Power technologies, which have been an integral part of the production facility in the Azzano Decimo (PN) plants for many years. The plants have recently undergone an upgrade with the introduction of new machines that have been designed to meet specific productivity targets while also meeting the company's exacting aesthetic standards for a high-quality finished product. 

A winning choice for growth 

The adoption of Prima Power's solutions has been a pivotal moment in Fhiaba's growth trajectory. Specifically, the company's operations are dependent on the performance of several pieces of equipment, including a Combi Genius 1530 punching and laser cutting system with an LSR (Loading Stacking Robot), a Shear Genius 1530 punching and shearing cell with a high-capacity STS (Sheared Part Stacking System) and LD (Loading System) automatic loading and unloading system, and an Express Bender 2220 FM panel bender. These technologies are integrated into a single flexible manufacturing system, the PSBB, which is enhanced by the presence of the Night Train FMS, an automated storage solution also designed and built by Prima Power. The process is overseen by NC Express, a high-performance scalable programming system. The system's advanced toolpath generation and optimization algorithms enable enhanced automatic programming. "Our company has over fifty years of experience in sheet metalworking," states Baron Toaldo. "It all started with the predecessor companies that my father founded. As well as experience and expertise, we had to make sure we got the right kit for the job. That's why we bought a Night Train FMS Flexible Manufacturing System from Prima Power in the early 2000s, which came complete with one or two other machines."  This technological suite has revolutionized certain aspects of sheet metal handling and management within the company, streamlining processes and markedly enhancing the quality of the final product. "From the outset, this equipment has brought considerable satisfaction and the reassurance that we have made an excellent choice," states Baron Toaldo. "This is because the Night Train FMS is highly flexible and aligns with our order types, enabling quick and easy changes to production processes and improved flows. It also lets us to increase the quantity of items that can be produced." 

Automation and quality in one 

Integration of the Prima Power system has significantly enhanced Fhiaba's production capabilities. The combination of automation and quality control in the machining of medium-thin thicknesses is a winning formula. "The great management capacity and perfect handling of the sheet metal were key factors that convinced us to buy the Night Train. It allows us to manage both raw materials and semi-finished products automatically," says Baron Toaldo. Fhiaba's machines, including the Shear Genius shear/punch combination and the Express Bender panel bender, are integrated into a flexible production line that is linked to the Night Train FMS, offering great versatility. The Night Train FMS has recently undergone a redesign that further optimizes its performance. "In short," states Baron Toaldo, "our plant is fully capable of producing 100% of the sheet metal requirements for our refrigerators. This configuration allows us to process batches of varying sizes with exceptional efficiency, whether small or of significant numerical importance, while maintaining the highest quality standards. The introduction of the Combi Genius 1530 punching and laser cutting system with a material and part handling robot has also broadened the scope for machining operations. This new system enables the production of parts with specific requirements, such as threading and other machining, thanks to its extensive tool range, which allows the part to be completed." The result is an optimized production process that ensures the highest quality standards for Fhiaba products. 

Digitized processes for improved manufacturing efficiency 

As anticipated, Prima Power's integrated NC Express software oversees all processes, representing another significant advancement in Fhiaba's production. "Its implementation in the plant has introduced another significant innovation and a substantial transformation in our operational approach," states Baron Toaldo. "Integrating the NC Express environment with our ERP 4.0 has enabled a two-way data flow between the two systems. This ensures seamless data transfer with no loss of information, providing a robust and secure environment for managing production processes." This integration has set the stage for future interconnection developments, which will further streamline production management processes. "Consequently, the number of errors made during the initial stages of manufacturing and production launches has been significantly reduced," states Baron Toaldo. "Optimization of machine scheduling has, in other words, significantly reduced errors, thereby increasing overall production efficiency." This level of software integration not only improves productivity but also establishes a foundation for future innovations in the field of luxury refrigeration at Fhiaba. "The added value of using this articulated system," Baron Toaldo states, "is the product quality, as there is no human intervention in material handling." 

Future vision: expansion and continuous innovation 

Fhiaba is all about future growth and expansion in the luxury and high-end refrigeration market. "Our vision,” says Baron Toaldo, "is to grow in all markets with new and improved food preservation and home kitchen solutions. Innovation remains a core element of the company's strategic approach, as evidenced by the numerous international patents developed and filed over the years.” To drive growth, the company plans to expand the application of Prima Power technologies, with a focus on the bending stage within its product development cycle. "We’ve already got new projects in the works," Baron Toaldo confirms, "We're planning to invest in Prima Power technologies for the bending part, with the goal of improving product quality and expanding the range of products we currently offer.” These investments are all about strengthening Fhiaba's position as a trailblazing and market-leading company in the premium refrigeration sector, both nationally and internationally.