High-Quality Housing for Continuous Underwater Use

15.08.2024

Serial production of a new, innovative counter-current swimming system for pools began in 2024, developed by a leading manufacturer in the field. This state-of-the-art system uses plastic components produced by Fried Kunststofftechnik, offering a groundbreaking solution for use in saltwater pools. Our client, Mr. Frank Wetzstein, shares insights about the project.

Collaboration and Project Start

The collaboration for the development of a new project started with a targeted internet search. Mr. Wetzstein, the responsible Supply Chain Manager, explains: “We chose Fried as a partner due to the availability of large machines and production facilities. Fried is a leader in Europe for the production of large-format plastic parts.” This cooperation started at the beginning of the development phase and led, through close collaboration, to a product launch in early 2024.

Range of Use and Product Benefits

The counter-current swimming system is installed in the wall of a pool and consists of a main housing, the installation box, in which a turbine is placed. While these systems have traditionally been made of stainless steel, the demand for saltwater-resistant and light pool solutions is growing. Mr. Wetzstein elaborates: “To meet these market demands, we developed a plastic product together with Fried that withstands these specific requirements.”

Scope of the Housing

The main housing of the counter-current system consists of seven plastic parts, including sealing frames, cover grilles, turbine inserts, and an LED ring. These parts are delivered separately and assembled by the customer. “We plan to produce 500-1000 housings per year, with the potential to reach up to 1500 units annually,” says Mr. Wetzstein.

Challenges and Solutions

Material selection was a particular challenge. Initially, a glass fiber-reinforced plastic was used, but it proved to be suboptimal. After extensive testing and adjustments, a material mix of ABS and PP was used, which perfectly met the requirements. “The adhesion and sealing of the LED rings were also challenging, but together we found an optimal solution,” emphasizes Mr. Wetzstein.

Injection Moulding Process and Advantages

The components are manufactured using the injection moulding process. Mr. Wetzstein explains the choice of the process: “The first prototypes were produced using the PU process, but the wall thickness and weight were not ideal. Injection moulding offered better aesthetics and lighter components that can be installed by a single technician. The weight of the system is very important during installation at the customer’s site.”

Customer Service and Quality

The quality of the plastic parts has already been confirmed in short tests, the long-term tests are still pending. Mr. Wetzstein praises the collaboration: “Customer service at Fried is very competent and professional. Weekly meetings were always well-prepared, and the performance in design and project development was outstanding. It was a pleasure working with the Fried experts!”

Unique Strengths of Fried

What sets Fried apart from other suppliers? “Fried is 100% focused on custom parts and has no products of their own in their portfolio. This specialization and flexibility make Fried a unique partner,” highlights Mr. Wetzstein.