How we do it
Our method, our passion
It is in this phase that the Italtower Staff design philosophy emerges. Mechanical design represents the first stage in the construction of a light tower
The production phase includes the cutting of carpentry and poles, painting and assembly of all these components with the generator developed by us.
The final check includes a series of activities necessary to establish the suitability of the product before putting it on the market. Complete test procedure that allows 100% operation to be tested.
After-sales support is one of the most important phases that Italtower wants to provide. Customer-specific technical assistance for warranty and spare parts.
1 Product Design
Design & engineering
The Italtower Staff design philosophy emerges at this stage, with simple solutions realizing innovative and functional ideas because producing good products does not necessarily mean to make expensive products. Together we define shapes, colors, surface finishes for the new product and any detail with all the possible design variation, including customers' requests, be them aesthetic, ergonomic and functional. Mechanical design is the first stage in the construction of a light tower with assembly drawings, details and material lists. Italtower's technical staff carefully manages each step of the project, which is essential for optimizing and controlling timing and, above all, costs.
The making of prototypes is an important step before starting the industrial processes of the product, since it allows to carry out the dimensional, functional and stability verification before the serial production. We create a functional prototype to highlight all the important points of the machine
We analyze any design problem that has not emerged in the 3D design phase
We perform all the researches and market tests, exhibiting them to events or giving them in use and verification to our distribution partners.
The first phase to deal with is the feasibility analysis capable of giving substance to a project.
It's essential to collect all the fundamental points of the project including the critical points so that any problems can immediately emerge in order to be able to fix them before starting with the design. A complete study of the materials, the choice of suppliers and a program of the production process will follow.
Once the three-dimensional project has been loaded we proceed with the sheet metal cut.
In laser cutting a beam of radiation is generated, focused by means of a lens on the surface of the sheet to be cut which heats up and quickly reaches the melting point.
At the same time a flow of gas coming out of a nozzle placed above the focusing lens produces a thrust sufficiently intense to remove the molten metal, generating a cutting groove. The process goes on by moving the laser beam and the sheet metal along the desired cutting path.
The advantages of laser cutting are not to leave irregular edges but to be able to make very clean cuts. With laser all the types of bore are performed with great precision, with total absence of burrs, high precision and speed, moreover particular shapes can be easily obtained.
The use of laser technology in cutting the square tube allowed us to obtain significant advantages in the innovation of the production process, and a high level of quality.
Improving processes such as drilling, slots, notches allowing perfect couplings without burrs and an optimization of subsequent welding operations reducing processing times.
Working with 3D projects the job scheduling is quicker and more effective.
Galvanizing is the process of applying a zinc coating to a metal product, generally made of steel, to protect it from galvanic corrosion.
Italtower realizes the galvanizing process on all the moving parts of its lighting towers using the electrolytic galvanizing method.
This type of processing is known as "cold" galvanizing. The end result is an optimal product both in terms of aesthetics and functionality.
In electrolytic galvanizing the material to be treated is adequately prepared in 3 main phases: the preparation of the surfaces to be treated, the coating and the finish.
All our components are pre-degreased, pickled and finally degreased, they are then immersed in an electrolytic solution containing zinc salts. Finally, the last passivation phase guarantees greater resistance to corrosion.
All the Italtower products are treated with powder coating. This fundamental finishing step has two very important purposes: the aesthetic characterization of the products and a functional improvement. This last effect is due to the fact that the layer of paint makes metal more resistant to wear and degeneration once in contact with the external environment, prolonging its duration in time. Thermosetting powder coating guarantees excellent mechanical and aesthetic properties that make the treated objects resistant to atmospheric agents, guaranteeing their protection over time.
Every detail goes through a complete treatment following these steps:
- Phospho-degreasing tunnel
- Oven drying at 160 °C.
- Cabin for powder coating first manual and second automatic part
- Electrostatic powder bonding
- Oven cooking with automatic temperature control based on the polymerization of the different powders and the thickness of the materials to be painted.
Every single phase of the assembly process is meticulously optimized, with a rigorous control of the logistic aspects of moving the components in line and between the line and the warehouse. The employees take care of the supply of materials for the assembly and the handling of the finished products.
Workstations, assembly lines, and handling are constantly monitored, so we are able to improve progressively the assembly level .
Organization of warehouse stocks and restocking, arrivals and shipments.
By means of management software we guarantee constant monitoring of both warehouse stocks and production commitments and in the production lines started. Each operator is trained on the importance of keeping data regularly updated in order to avoid errors on stocks and stocks.
Italtower is able to manage the continuous variations of the production plans, each of our operators is interchangeable allowing the variability of the light tower to be assembled.
The wide range and customizations required made us highly flexible and available to market demands.
Tests and quality
The term 'test' defines a series of activities necessary to establish the suitability of the product before putting it on the market. Italtower has chosen a complete test procedure to test the 100% performance of the light towers.
The Italtower technical staff carries on the following tests and checks on every machine:
Functional efficiency test.
Proof of effectiveness.
These checks make it possible to verify the functioning and performance of the light tower be it electric or with an internal generator; during testing with an internal generator the light tower undergoes an electrical load to simulate operation in the most severe condition of the generator.
Italtower follows firsthand every step of this process, a competent and professional team will help you decide the best shipping option monitoring the goods up to the final destination . The Product packaging is an aspect Italtower pays close attention to. Shipped by road or incontainer, your light towers will arrive safely in the shortest time.
Italtower offers 1 year warranty for each product which can be extended up to 24 months. After a brief report of the malfunction of the component Italtower will replace it quickly. Our Service is constantly available for our customers. Italtower has an international distribution network with qualified companies able to provide an excellent service to the end customer.
Components and spare parts
The ideal solution for every light tower Immediate availability in our spare parts warehouse. Available in 24 hours to organize any shipment of components to our dealers thanks to a widespread and efficient logistics network.
✓ Certified reliability of the original components range, totally managed by Italtower and with the collaboration of our selected supplier partners.
✓ Lower operating costs and greater residual value in the warehouse
✓ Assistance and experience thanks to a technical staff that knows the products to the smallest detail.