Second welding robot fuels 25-30% production increase at Container Modul

Container Modul produces specialised platforms and hook-lift containers for trucks, and since 2020 it also produces trailers. In 2022, the first welding robot was purchased for the production of container components, and a year later the company decided to invest in a large welding station for complete large-scale products.

Container Modul

Container Modul employs around 170 people and supplies its products mainly to the Scandinavian market and, to a lesser extent, to Germany and Switzerland. "Our priority is to tailor our products to the individual customer needs", says Katarzyna Okuń, Director of the Ryman plant. "Our products are characterised by their high volume and low tare weight. We achieve low weight by using high strength steel with high abrasion resistance and hardness." The robot has to meet these requirements by automatically correcting the torch movement trajectory (thanks to the adjustment of dimensional tolerances of large products) and welding difficult-to-weld materials, while also allowing for easy and fast programming of new products.

Teamwork has brought results

"Before purchasing the first robot, we had no experience in robotic welding. Coordinating all activities and acquiring the right skills proved to be the most challenging part", says Piotr Hawrylak, Director of Technical and Production. Container Modul opted for a step-by-step approach to robotic welding, buying a smaller station first and then a larger one. The small station welds container components and spare parts for containers as service parts, while the large station welds complete vehicle containers. The welding fixturing mounted to the positioner was designed and manufactured in-house by Container Modul. Visiting companies that use Valk Welding's robotic systems allowed them to select the most optimal welding jig concept.

Quality matters

"We put a lot of emphasis on the quality of our products, which is one of our differentiators and competitive advantages", says Piotr Hawrylak. Proper preparation of the parts to be welded is important in manual welding to ensure high quality, but it is even more important in robotic welding. It helps to reach full production on the robotic station faster and to achieve the right quality and efficiency. Earlier processes such as precision cutting or sheet metal bending are also important to the final result. Adapting production for robotic welding sometimes requires structural changes to the manufactured parts, but all with the aim of achieving an optimised design that reduces production costs while improving quality.

Production increase of 25-30%

"The most important benefit is the possibility to increase production by 25% to 30%. Given the current shortage of skilled welders, this is a big plus. The operator does not have to be a welder, so it is easier to find such a person in the labour market", explains Piotr Hawrylak. Container Modul already employs three women as robot operators, and they are doing an excellent job. To facilitate work at the robot station, it is equipped with a number of functions that make the programming and welding process easier. This involves offline virtual robot programming using DTPS software, as well as full sensor capabilities such as Quick Touch Sensing and the ARC-EYE laser camera. These functionalities are essential tools for the Valk Welding robot systems at Container Modul.

Offline DTPS programming reduces implementation time and allows quick adjustments to the robot program.

Tomasz Kozłowski, robot programmer at Container Modul.

Choosing the right integrator

Container Modul began considering robotic welding of its products several years ago. "We talked to a company about introducing this into our products, but the project did not materialise because they could not meet our requirements", says Tomasz Piskorz, Production Manager. "After a few years, the subject resurfaced and we started looking for a company again. We invited several companies for discussions, including Valk Welding. We had to turn down many companies due to their lack of experience in welding products similar to ours. Through conversations and reference visits to companies where Valk Welding had installed its robots, we realised that this was the right direction to take", concludes Tomasz Piskorz.


Download the full Valk Mailing



We like to think along with you in finding solutions for your (welding) automation, welding wires and welding accessories. We are looking for the connection and prefer to be a partner rather than a supplier.