“The first thing to do,” he said, “is to find the best supplier with the best products that we can rely on.”
“Then,” Rivolta added, “we assemble machines in Italy, after they are assembled, they are commissioned and tested so there are no problems. There is a thorough paper trail and everything is electronically recorded as well. This includes the serial numbers of the parts.
“So if there is a problem in the future, we can contact the supplier. This process enables us to get our CE Mark.”
Romano added: “Our ISO consultant said that we operate an island production system, with the technicians involved in all phases of the production and assembly. There is no serial production since machines are mostly tailor-made."
In one case Ekosystems specified a continuous rigid panel line that used a roll-forming machine from China.
Rivolta said: “Ekosystem supplied the wet part, the double belt and dry parts of the machine came from China.
“We visited the Chinese plant with our customer, to check all the parts as they were put in the content of shipment,” he added.
Young and experienced
Although the firm is young, its staff have polyurethane industry experience. Rivolta has over 30 years’ experience in the polyurethane industry starting work at 19 and as a processor.
Caglio said: “In the beginning, we worked from my home, with technical assistance and spare parts. In 2004 we sold our first machine to India to a company called Harita .
She continued: “After we sold the first machine, the number of enquiries increased and we had to move to the first factory.
“We were there for 10 years, and then two years ago, we won a big bid and the space we had was not sufficient. We had to make 30 low-pressure machines in a workshop which was 300 m²,” Rivolta said. “Every time the machine was made we put it in a box in a container.”
“Then we decided to buy this building,” Caglio said, “We were growing and so we needed more space.”
The firm moved to a new 1000m² factory, located in Desio, about 15km (9miles) north east of Milan, in September 2015, said Romano. There is an additional 200m² of office space at the site.
Ekosystem, which had taken on extra technical staff ahead of the move completed construction of a 30m double metal-faced rigid panel line in mid-December 2015. “Moving to new premises made it possible for us to complete such a large machine,” Romano said.
“The new building was also used to produce some repeat business for the firm,” she explained.
“We have had a relationship with this customer for five years, their base is in Saudi Arabia and they trust us, they gave us this order because were not just good in words we’re good in facts,” she added.
“At the moment demand is for high-pressure machinery, but two years ago, we produced several low-pressure machines.
Rivolta explained: “The largest number of machines we produce are for low-density rigid foam panels for domestic refrigerators and boilers as well as some moulded and flexible foam.”
Ekosystem has also worked on pentanisation projects with International organisations
Rivolta said: “At the moment customers use water and 141-b, blowing agents.” Ekosystems modifies machinery for use in hot temperatures “We increase the cooling power with a bigger heat exchanger, and usually we suggest putting machines inside air-conditioned rooms as the best solution. Usually when I meet a processor all of the drums and so on are in an air-conditioned room,” he added.