Aboutcamp BtoB n.8

Editor’s note

EDITOR-IN-CHIEFAntonio MazzucchelliMob. +39 3355338977Skype: antoniomazzucchelliE-mail: [email protected]

STAFFJörg Nullmeyer - Andrea CattaneoGiorgio Carpi - Maurizio FontanaMauro Nogarin - Gabriel LopezSilvia Sacchi - Enza PirreraLuciano CorsiniVincenzo Francofonte

Aboutcamp NetworkVia Benvenuto Cellini 1620129 Milano - ItaliaTel. and Fax: +39 0258437051E-mail: [email protected]: www.aboutcampbtob.eu

Aboutcamp is a magazine registeredwith the Milan Court on 7 Oct. 2009at No. 427

aboutcamp BtoB

ISSUE 8 December 2014

D ometic Group took over the Prostor RV awning division from Belgian company, Brustor NV. Prostor isone of the leading European manufacturers of awnings for RV´s, with this acquisition Dometic have

access to a complete range of awnings and accessories primarily for Europe and Australia. The Prostor BikeRack range (E-Bike Lift) and the Prostor Parasol division are not part of this transaction and will stay in theBrustor Group. Dometic is already one of the largest manufacturers of awnings world-wide for RV´s,however, these products are designed and produ-ced for the North American markets. Prostor hasmore than 30 years of experience in production ofawnings and are known for innovation, lowweight, and high quality. Prostor production facili-ty is located to Geluwe in Belgium. “We believethat we have taken Prostor to a point where con-tinued growth can only be materialized if thecompany is part of a larger organization with aglobal distribution and after sales support. Thereare very few such companies and we have foundthat Dometic Group is the best “new home” forProstor” says Olivier Rogiest at Brustor NV.

RV registrations increased in Australia

T he latest Caravan & Campervan Data Report shows an increase in recreationalvehicle registrations in Australia. The report, commissioned by Caravan

Industry Association of Australia, found that the number of caravan in Australiaregistrations have experienced a higher rate of increase than any other vehicle typein the last two years. In 2013 the number of registered RVs in Australia was528,869, jumping from 502,025 the previous year. Of these registered vehicles474,783 are towed product while 54,103 are motorised. RV production statisticsfor May 2014 are up 7.4% since May 2013. They also show the highest towablesproduction in at least six years and the highest combined total since March 2011.

This new issue is printed between the two mainRV shows: the 52nd Annual National RV TradeShow and the Düsseldorf Caravan Salon. The

German show was the best attended edition in its histo-ry and confirmed the leading position as the world’s lar-gest trade fair for motorhomes and caravans: 192,000visitors, 28,200 vehicles in the trade fair’s own campsiteand 580 exhibitors from 25 countries. We think thatnext edition of the Louisville show will be relevant aswell, as the US market is growing fast. In September2014 RV shipments are 10.5% greater than this sameperiod one year ago and this was the highestSeptember level in seven years with increases in all thevehicle categories. We are going to close ore fourth yearof life and we are satisfied by congratulations andencouragement from many readers around the world.As we want to improve and innovate every day, wouldyou have any suggestion, please just write to me [email protected] and I will be very happy to getyour feedback. (Antonio Mazzucchelli)

Dometic acquired the Prostor RV awning business

Focus on: LAIKApage 3

22

News MARKET & PRODUCTS

Lippert Components, Inc.(LCI®) and E&P Hydraulics

announced that E&P will sell anddistribute LCI products, includingIn-Wall® Slide-Out systems, win-dows and electronic controlsystems, on an exclusive basis tothe European caravan andmotorhome market. E&PHydraulics is one of Europe’s lar-gest suppliers of hydraulic leve-

ling systems and supports an extensive service network throughout Europe.“We have been supplying E&P Hydraulics premium components for nearlya decade and we highly regard the company and its people,” said LCI ChiefExecutive Officer Jason Lippert. “E&P manufactures exceptional productsand is well respected by European manufacturers. We believe that buildingrelationships like this one will help us reach customers and find success inEurope.” E&P founders Eric Klinkenberg, Pierre Blom and Kay Fischer haveworked with LCI since 2005 and are pleased to expand the relationship tooffer the full line of LCI products. They said the long-term and successfulcooperation between the companies was instrumental to entering into thisrelationship. "We have proven to the European market that we offer a greatproduct with exceptional service," said Fischer. "Our regional teams acrossEurope have developed extensive networks with manufacturers by provi-ding the best product solutions."

Dexter Axle, a manufacturer of trailer axles, brakes and hubsand drums for over 50 years, has acquired the North American

assets of AL-KO Axis Inc. AL-KO Axis is a manufacturer of axles andother components for trailers and towable equipment in the utili-ty, recreational vehicle, heavy duty, manufactured housing, agricul-tural, marine and specialty markets. As part of the transaction, theAL-KO Kober Group will become a shareholder in Dexter Axle, andStefan Kober will join the board of directors of Dexter Axle. “Weare thrilled by this acquisition and the positive impact it will haveon our combined customer base,” said Adam Dexter, presidentand CEO of Dexter Axle. Stefan Kober, CEO of the AL-KO KoberGroup stated, “Over my time in the axle industry, I have recogni-

zed the similarities in AL-KO’s andDexter’s business principles of striving foron-time and complete delivery, produ-cing high quality products, and offeringsuperior customer service. I believe thatour customers and employees will appre-ciate the additional resources that Dexterwill bring to this pursuit.” Dexter Axle ismajority owned by a fund managed byThe Sterling Group, a leading privateequity firm based in Houston, Texas, with over $1 billion of assetsunder management.

E&P Hydraulics and Lippert Components in Europe

Tecnoform has becomein the latest years a

trendsetter in the world ofRV interior design, combi-ning modern creativity toclassical elegance andindustrial process know-how. Tecnoform is todaynot only a worthy repre-sentative of “Made inItaly” products, but a com-mitted Company to what“Italy will Make”. «2015 will mean to Tecnoform50 years of activity. A special surprise is being plan-ned for the next Caravan Salon Edition, meant toexemplify the Company’s experience and contribu-tion to the market – said Roberto Kerkoc,Tecnoform Managing Director - It is likewise hard totell what the next 50 years of Tecnoform hold instore. But we do know some of the big challengeswe will have to deal with : fostering competitive-ness, investing in high technology manufacturingtecniques, promoting new product developments,ensuring stability in an ever-changing, complex andunstable global market».

Dexter Axle acquires AL-KO Axis

Stefan Kober

CIVD has a new Executive BoardHermann Pfaff, CEO of Hymer BusinessDevelopment GmbH, is the new president ofthe Caravanning Industry Association (CIVD),elected by a large majority during the AnnualGeneral Meeting at the Caravan Salon inDüsseldorf. He is replacing Klaus Foertsch,Managing Director of Fendt-Caravan GmbH,who after 12 years is stepping down from the

helm of the association.Ulrich Schopp, Managing Director of LMC Caravan GmbH & Co. KG andDr. Holger Siebert, CEO of Eura Mobil GmbH, were confirmed. Moreover,Klaus Dieter Böcker, CEO of Hobby Wohnwagenwerk Ing. HaraldStriewski GmbH, and Werner Vaterl, Technical Manager of Knaus TabbertGmbH, were newly elected to the board. Jürgen Vöhringer, ManagingDirector of Vöhringer GmbH, was approved by an overwhelming majori-ty of the representatives of the industrial suppliers (group III) in his role.

Derald Bontrager Elected RVIAChairmanDerald Bontrager, president and CEOof Jayco, Inc., was elected RVIAChairman of the Board for fiscal year2015 during the association’s Board ofDirectors meeting on Sept. 24, 2014 atThe St. Regis Aspen Resort in Aspen,CO. “The Board has elected one of the

most well-liked and respected leaders in the RV industry tobe the association’s next chairman,” said RVIA PresidentRichard Coon. “Derald is a veteran of the RV industry andhas been a very engaged member in the association formany years. In that time, his insight and business experti-se at Board and committee meetings have been invaluableto the association. I am looking forward to working withhim in the coming year.”

continue to page 32

Faces and careers

Tecnoform: the present and the future

Roberto Kerkoc

Focus on LAIKA

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A closely-knit teambackstage

It is definitely one of the best knownItalian brands in the European cara-van industry, perhaps the brand that

has best represented the Italian Stylethat according to many is the prime cha-racteristic of Italian manufacturing:Laika has recently reached the milestoneof fifty years in the business and over theyears it has made a significant contribu-tion to the culture of outdoor holidays inEurope. We were able to exchange ideaswith those at Laika who are most com-mitted to the delicate process that startswith an idea and leads to the productionof a new vehicle: Roberto Viciani isresponsible for the technical depar-tment, while Francesco Gabbrielli coordi-nates research and development. It wasan edifying interview that touched ontechnical issues and helped us under-stand how, even amid the ups and downsof a manufacturing sector that has notbeen spared by the economic crisis, acompany that operates in the premiummarket can and must aim for excellenceby working together on quality andstyle, making research a vital factor in

development.The creation of a new vehicle in a com-pany with industrial production levelslike Laika comes about in stages andinvolves various professional roles. First,all the results that emerge from a carefulstudy of the market are put on the table:in the briefing where the features of thevehicle to be realized are outlined, theproduct manager brings to the discus-sion the advice of Laika dealers, whohave a direct relationship with both realand potential customers. After approvalof the basic concepts, the ideas begin tobe developed and are transferred topaper or screen: simple pencil sketches ormore sophisticated drawings, virtual pro-cessing and rendering – basically every-thing needed to outline style and fun-ction proposals for the vehicle. Work isdone both on the overall look and theinternal living conditions – it is thus a360-degree design proposal. There issome trial and error, and proposals aredrawn up and full-scale maquettes aremade, obviously with different executiontimes and methods, depending on the

size of the vehicle. Then comes the next stage: defining thedetails. The various issues are examinedin detail, with an in-depth analysis of thevarious materials. The shapes are studiedin 3D and the best way to construct themoulds is discussed, finally addressingthe choice of suppliers. «As far as the most important compo-nents are concerned – says RobertoViciani – there is continuous dialoguewith suppliers. Consultation is not onlypro-active, but on-going, to ensure thatthe forms selected can be industrialized,to verify the maintenance of high quali-ty and to make sure no problems arisethat could decrease the reliability of theproduct. Together with our suppliers, wechoose the most suitable materials, themost suitable machining and the bestcomponents in order to guarantee pro-duct durability. After the materials andprocesses have been chosen, we proceed

We met with two key figures for the development of Laika products – an important Italian brand in theEuropean market – Roberto Viciani, head of the technical department, and Francesco Gabbrielli, head of R&D.

Words Antonio Mazzucchelli

Roberto Viciani e Francesco Gabbrielli

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Focus on LAIKAto a more detailed design phase, definingthe mathematics of the individual pieces andbuilding a prototype that puts all the piecestogether. Compared to the past, we aremuch faster now: thanks to new softwarewe can create simulations that correspondperfectly to reality.»At Laika we are striving to realise a highlycustomized product – even in the minordetails. Our suppliers must adapt to thisapproach and interact with the technicaldepartment to find the best solutions.Sometimes parts are made especially forLaika, other times Laika may detain theexclusive rights to a product for its first year,testing it beforeothers do, there-by creating atrend that otherswill inevitablyfollow. I n n o v a t i o ndepends vitallyon research andexperimentation,and as has alwaysbeen the case inthe recent historyof industrial pro-ducts, new solu-tions are oftenfound by basingresearch on high-end products.Laika has operated in this way in the past and still does: a com-mon thread runs from the first Motorpolo models of the 1970sto the Rexosline 9009 of 2012 – the stated aim was to produce

a top quality vehicle that could enable some new solutions tobe transferred to the entire production line. The head of theResearch and Development Department of Laika, FrancescoGabrielli, explains further.«With the Rexosline 9009 we tried to push innovation as muchas we could – says Gabbrielli – and we worked a lot on thematerials and on the types of solutions and the furnishings. Wewere able to cast pieces that until then were considered impos-sible to cast. And on the 9009 we experienced combined ther-moformed fabric printing, which is a fabric joined to a plasticcomponent – in this case a wall-mounted cupboard – not bysimple bonding, but by uniting them directly in the productionphase. Behind these results there is a whole history of pastexperiments, of trial and error, of moulds and counter-moulds,and the implementation of certain processes was very costly.Now that the direction is clear, products like these can be rea-lised at lower prices and with greater final quality: lead timeshave been reduced and assembly accuracy has increased, andso also the quality of the finishes.»The search for new solutions has been only one of several chan-ges made in the way vehicles have been manufactured inrecent years, as Roberto Viciani confirms. «Among the changes regarding the exterior of the vehicle, wemust certainly mention the introduction of plastics – says thecoordinator of the Laika technical department – sophisticatedplastic materials that have been able to replace traditionalfibreglass components. No longer monoblock components,these lighter pieces now allow an element to be broken downinto several parts. This can be seen in the side skirts and also inthe rear bumper. With regard to the body, a big step forwardhas been made with the introduction of polyurethane framesin place of traditional wooden slats. But we have also workedhard at finding new materials for the interior of the vehicle.Just think of the bathroom sinks, which were previously in ABSand are now made of special resins – they’re even soft to the

One of the first Italian companies to build campingvehicles, Laika has undoubtedly contributed to thehistory of the industry. It was founded in Tuscany in

1964 thanks to the initiative of Giovanbattista Moscardini,a manufacturer of caravans. In 1977 the first RVs hit themarket: the Motorpolo line, high-end vehicles that imme-diately established the standards the competition wouldhave to meet, but also expressed style and innovation, set-ting the stage for the company’s future products, includingthe Lasercar series in 1997, the Ecovip in 1992 and theKreos of 1999. The company’s mission is to build top-tier campers thathave a strong and unmistakable personality and combinehigh quality, Italian style and innovative and functionalsolutions. Modern lines inspired by the automobile, lightscreated exclusively for Laika, interiors that evoke theworld of sailing: these are just some of the elements thatdistinguish Laika products. Becoming increasingly identified as an industrial manufac-turer, the company in Tavarnelle Val di Pesa has demon-strated its ability to deal with market expansion andincreasingly fierce competition, and it benefited from itsentrance into the most powerful group in the Europeanindustrial sector, the Erwin Hymer Group, which cameabout in various stages starting in 2000. The most recentmajor project of the Tuscan manufacturer is the creation ofa large new factory not far from the older one, with a pro-duction capacity of thousands of vehicles per year.

Company Profile

touch.»The partial replacement of fibreglass with pieces in ABS hasreduced the weight of the body, just as greater payload capa-city has been gained by using internal polyurethane frames(density 350 kg/m³) instead of fir wood (450 kg/m³).The use of appropriate high-performance materials is also offundamental importance to providing the vehicle with thenecessary insulation. The Tuscan company was among the firstyears ago to use Styrofoam (extruded polystyrene foam) forthe production of sandwich panels, and for years it has adop-ted a double floor to isolate the living compartment in the bestway possible. «We were the first to use LED lights to illuminate 100% of theinterior – said Roberto Viciani – and LED lighting was truly arevolution and resulted in significant energy savings. A LEDlight bulb consumes only 20% of the energy of a halogen bulb.Today, an RV can be hassle-free all weekend long withoutbeing connected to an external power supply, and this meanssignificant advantages for the user.»The evolution of style and materials follows the progress indesign and technology of other sectors and benefits from acomparison with other cultural areas and with different indu-strial products. «We perform a detailed annual analysis of two productive sec-tors that have a lot in common with ours – says Francesco

Gabbrielli, head of R&D at Laika – the automotive industry andthe furnishings sector. We try to figure out where design is hea-ded, what the trends are, and we start by looking at vehicles –passenger cars as well as trucks and buses – and a comparisonof their external lines is essential, but we also look closely atthe furnishings industry, to see how it compares with the inte-rior of our vehicles. And the interior often shares characteristicscommon to the world of sailing. Inside the camper, the study oflight is becoming increasingly important – the relationship bet-ween shapes and colours of the furnishings on one hand andnatural and artificial light on the other.» But Gabbrielli points out that the vehicle’s exterior is subjectedto careful study in order to understand how to develop boththe graphics applied to the sides and the colours chosen for thevehicles. At the design stage we perform several trials, someti-mes testing very risky ideas or proposals that might remain onthe drawing board because their time has not yet come, butafter a few years may become the standard. «As for the colours and graphics – said Roberto Viciani – wehave to deal with classically-oriented customers who want pro-ducts to be innovative, sure, but don’t want them to be exces-sive, aggressive or exaggerated. Laika’s products are innovativeand trendy, but they are still simple and tasteful as well. Andthis is perhaps the greatest challenge that we face every day atLaika.»

5

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A lu-Line GmbH has beenan absolute specialist forthe processing of alumi-

nium for more than 30 years andis a high-precision manufacturer.Being a supplier for the automo-bile and medical technology industries, therequirements regarding weight-savings andstability are nothing unusual for thisSwabian firm. Lightweight construction isalso gaining in importance in several indu-stries, included the motorhome industry, asa consequence of the increasing customerrequirements and of the limitation of dri-

ving licences to a total weight of 3.5 tonneswhich is taking place in many countries.Alu-Line has been selling its own, high-qua-lity accessories range for motorhomes andcaravans for more than 17 years now underthe name ‘EuroCarry’. Alu-Line producesproducts both under its own name andaccording to manufacturer’s specifications.This large vertical range of manufacture is a

clear advantage over its competitors. Thecompany’s own very modern developmentdepartment is able to solve technical pro-duction problems during construction,resulting in faster prototype production andthus earlier product availability. The finishedproduct can be delivered just in time to theproduction belt of the motorhome or cara-van manufacturer on request.

Precision in aluminium

Alu-Line Metallbearbeitungsgesellschaft GmbH Martin-Staud-Strasse 25 - D-88348 Bad Saulgau - Germany

Ph: +49 758148840 - E-mail: [email protected] - Web: www.alu-line.de

Words Jörg Nullmeyer

Alu-Line is an absolute specialist for the processing of the aluminium and is highly successful in the production of liftbeds. Vertical Move and Free level are the Alu-Line’s new beds with great stability and low weight

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Contact:Thomas Erban - [email protected]

Company Profile

Alu-Line is highly successful in the produc-tion of lift beds and manufactures approxi-mately 15,000 every year in 65 versions.The models ‘Vertical Move’ and ‘Free Level’are Alu-Line’s two new lift beds. These bedsare of interest to the manufacturers ofmotorhomes both because of their greatstability and their low weight. In contrast tobeds that are made of steel and oftenweigh over 50 kilograms, the ultra-lightstructure of the ‘Free Level’ bed weighs only20 kilograms while the ‘Vertical Move’ ver-sion weighs 12 kilograms more. This ismade possible by the extruded aluminiumsections that are produced specifically forthis purpose. The structure is then welded,rather than being riveted, which would bestandard for this kind of structure. Theresult is a high-strength connection that isresilient in the long term. Bearings from theautomobile and engineering industries areused for all moving parts. The ‘Vertical Move’ bed offers headroom of70 centimetres above the bed. The flatstructure of the scissor system requires only50 to 80 millimetres on the sides. The gascylinders used are specifically manufacturedas the result of many years of developmentat Alu-Line. In its basic configuration thebed is designed as a mechanical version.New, particularly quiet electrical motors canbe selected for a comfortable raising andlowering of the bed. The ‘Free Level’ lift bedoffers even greater weight savings. Thisultra-light aluminium structure weighs just20 kilograms with a structural height of

only 33 millimetres. This only limits headro-om very slightly and the structural height ofthe vehicle can be correspondingly lower.This bed is also available in manual andelectrical versions and can be lowered by asmuch as 90 centimetres. Its simple andtimesaving installation in the vehicle makesthis bed particularly interesting for serial

production.The beds are fully equipped on request, i.e.they are supplied complete with a slattedframe or mattress support system. Thisgreatly reduces the handling costs for themotorhome on the production line. Eachmanufacturer can adjust the panel and thebed canopy individually to the interior.

A lu-Line GmbH was established by Alfons Zimmerer inBad Saugau in 1985. The company quickly became well

known for its precision in the welding, punching, sawingand grinding of aluminium parts and profiles. The conti-nuing expansion of the operation necessitated the construc-tion of a further production hall at the current premises in1990. The second Managing Partner, Ernst Sigmund, joinedthe flourishing company in 1991 and a second productionhall with an integrated administration building had to bebuilt just four years later due to lack of space. The productshave been marketed across Europe under the brand name‘EuroCarry’ since 1997. An ultra-modern CNC departmentwas established in 2000 that enabled the processing of longaluminium parts with lengths of up to 6 metres on five-axis

machining centres. Certification in accordance with DIN ENISO 9001:2000 allowed Alu-Line to access new markets inthe automobile industry and in medical technology. Theofficial opening of a large, modern production and storagehall took place in 2009 and the entire ‘Planning andConstruction’ area was modernised two years later togetherwith the introduction of the ultra-modern CAD software‘Solid Edge’. The company has been certified in accordancewith DIN EN ISO 9001:2008 since the end of 2011. 87 mem-bers of staff are currently employed on the approximately9,000m² production and storage area. Alu-Line will be sup-plying customised laser parts from simple sheet metal partsto complex assemblies from 2015 in aluminium, steel andstainless steel.

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3A Composites - Airex AGIndustrie Nord 26 - 5643 Sins - Switzerland

Web: www.3ACCorematerials.com

BANOVA® grown light - made strong

BANOVA® PLY – light and solid

For recreational vehiclesweight plays an increasing-ly important role. Whether

more payload, lower fuel con-sumption or legal limits on thedrivers license - the customerwants the lightest possiblerecreational vehicle. Often opti-mization experiments of thedesign engineers did not fulfillthe expectations. With BANOVA®

3A Composites offers designersa material to slash weight.

BANOVA® is available as BANO-VA® PLY, BANOVA® PLY ILO and

BANOVA® FLEX. The base mate-rial for all three types is the same,they are made of FSC®-certifiedbalsa veneer. Balsa lumber is verysoft and light, with a coarse,open grain. The typical density isabout 160 kg/m³ (10 lb/cu ft).The balsa tree is the fastest grow-ing tree in the world. It can growfrom a tiny seedling to an adult30 meters (90 feet) high in aboutfive to seven years. 3AComposites owns and managesseveral thousand hectares ofFSC®-certified balsa plantationsin Ecuador (Plantaciones de Balsa

Plantabal S.A.). Its own cultiva-tion from seedling to the treeensure sustainable forest man-agement and local manufactu-ring enables to provide a conti-nuous supply of 100% FSC®-cer-tified products to industrialcustomers.

BANOVA® offers minimal weightand yet great stability - sustaina-bly! Moreover, BANOVA® can becombined with different materialsin order to influence specific pro-perties. So there are hardly anylimits as to where it can be used,

whether furniture and interiorsfor vehicles or walls ceilings andcomponents in construction. As asolid wooden material, BANOVA®

does not require any specialmachines or tools and it can easi-ly be processed by all interior out-fitters and cabinetmakers.Furthermore, conventional faste-ning solutions can be used becau-se BANOVA® does not require anyinserts or special fasteners. AllBANOVA® products are WaterBoil Proof (WBP) and MarineGrade, all bondings are free offormaldehyde (NAF).

BANOVA® PLY is a lightweight plywood consisting of adhesively bonded balsaveneers. Owing to the varying panel thicknesses, processing variants and itscombination with different facings, it is extremely versatile in use. When com-bined with facings such as aluminum, decorative hardwood veneers, HDF orbirch plywood, the properties of the material can be specifically optimized interms of rigidity, load-bearing capacity, impact resistance, scratch resistanceand visual appearance. Besides being lightweight and environmentally compa-tible, BANOVA® PLY offers the possibility of using existing woodworking toolsas well as connecting techniques.

3 A Composites (3AC) is a division of the publicly listedSwiss Company Schweiter Technologies AG, with a

world-wide leading position in composite materials,panels and components for architectural, transportationand display markets. 3AC is fully backward integrated inbalsa based products, owning FSC®-certified balsa planta-tions in Ecuador and conversion activities in Europe,America and Asia.

Company Profile

BANOVA® the sustainable weight saving solution for motorhome & caravan

BANOVA® PLY with aluminumBANOVA® PLY with high pressure laminate

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BANOVA® PLY ILO is abalsa veneer basedlightweight plywoodwith ilomba hardwoodfaces. The hardwoodfaces enhance the surfa-ce resistance and therigidity of the panel. Thesmooth and even facesmake it a good base for overlaying with ultra-thin decorative papers andfoils. This finish is broadly used in the caravan and RV industry.

Michael van Enschot - Sales Manager Europe [email protected] - Ph. +49 1722317343

New FRANKIA series T72 with BANOVA interior

The German RV manufacturer Frankia introduced BANOVA® in their new 3.5t Serie T72,launched at the Caravan Salon Düsseldorf 2014. Using BANOVA® for the interior cabi-netry reduces the vehicle weight by around 100 kg. “Weight saving is the biggest chal-lenge in the RV sector. BANOVA® is the solution to offer our customer highest payloadand comfort”, expresses Thomas Pfister, sales director at Frankia. The BANOVA® panelshave been laminated by the German Vöhringer Group, the leading supplier to theEuropean Caravan Industry.

BANOVA® PLY ILO with paper lamination

BANOVA® FLEX is a highly flexible bendingplywood used for curved components. Inconjunction with thin facings, small radiuscan be created with only one layer ofBANOVA® FLEX, where traditional bendingplywood would require two or more layers.

Besides being lightweight and environmen-tally compatible, BANOVA® FLEX offers thepossibility of using existing woodworkingtools as well as established connecting andbonding techniques.Just as BANOVA® can be produced with themost diverse properties, there are also hard-ly any restrictions when it comes to usingthem. Fronts, desktop and body parts of

furniture, panelling and cladding, floorpanels, structural components, industrialapplications.

BANOVA® PLY ILO – light with high end face finish

BANOVA® FLEX – light and flexible

BANOVA® FLEX

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Brianza Plastica SpA, Italian company with more than 50 years ofhistory dictated by innovation, research and development in thefield of FRP/GRP (fiberglass reinforced plastic or glass reinforced

plastic), has now established a US society: BRIANZA USA Corporation.The new company was created in January 2014 to serve the entire USmarket and to strengthen its presence in the territory, handling orders ofany size. Its headquarters in Elkhart are equipped with a storage ware-house and distribution centre, making it a reference point for the distri-bution of ELYCOLD and ELYPLAN fibreglass laminates destined for themarket of recreational vehicles (campers and caravans) and motor vehi-cles (trucks and buses). Brianza Plastica was established in 1962 tomanufacture fibreglass laminates and has continued to expand its pro-duction, operating mainly in the construction industry. Its range of pro-ducts, which includes Isotec insulation panels, is a true landmark forboth residential building and industrial construction industry. Takingadvantage of the knowledge coming from the production of the tradi-tional FRP/GRP, since the beginning the company wanted focusing on

the transport sector which led Brianza to now have two production sitesequipped with discontinuous lamination technologies and an expansionof the headquarters in Carate Brianza with a new continuous laminationproduction line.Brianza Plastica is among the largest European manufacturer of fibre-glass laminates and also the only company able to offer flat laminatesmade with two technologies: continuous and discontinuous productionlines. Over the years this sector had an increasingly important role in theeconomy of the company’s turnover and the strengthening of BrianzaPlastica’s presence in the USA is the confirmation of its ability to renewand evolve, meeting the needs of the market with increasingly moreinnovative products and a widespread production and commercial orga-nisation.The capability to provide laminates manufactured with "continuous"system and in high glossy " discontinuous " finishing, (both products arecoilable or cuttable to size) provides Brianza Plastica in a privileged andunique position to be able to meet any request coming from RV manu-

Brianza Plastica SpA - Via Rivera, 50 - 20841 Carate Brianza (MB) - ItalyPh: +39 036291601 - Fax: +39 0362990457

www.brianzaplastica.it - [email protected]

Brianza Plastica’s penetration into the world of recreational vehicles continues: the Italian company recently opened anew factory in Elkhart, United States. A choice made by the company to serve the entire US market and to strengthenits presence in the territory

Words Andrea Cattaneo

The new factory in US

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BRIANZA USA Corporation - 21099 Protecta Dr.Elkhart, IN 46516 - [email protected]

facturers, truck body builders, truck trailermanufacturers, speciality vehicle manufactu-rers, architectural panels and other customersdesiring innovative assembly and productionmethods. Doubtless, the continuous increase inthe use of the FRP/GRP for the construction ofRV as well as for refrigerated transport units,have made the FRP the main product of thepresent and of the foreseeable future. The mar-ket of the RV is constantly changing, as thetastes and needs of end users. Brianza UsaCorporation can provide laminates for any partsof the vehicles - interior walls, exterior roofs,floors - with coloured gelcoat finish or suitablefor painting. Thin laminates, as simple outerskin of the panel (0.039") up to high thicknes-ses (0.16") to replace the classic combinationFRP + LUAN.«ELYCOLD is our flagship product - said FilippoMilani, Brianza Usa Corporation sales manager- It is produced on plan moulds on where itends the cure time at room temperature. Thisprocedure gives to the laminate a total covera-ge of the texture, solving the blemish of thetypical marking of the fiberglass. We use onlythe best raw material available on the market,including anti-UV fillers that give an outstan-ding resistance against the yellowing. Our pro-ducts have been XENON tested at one of themost important and reliable US laboratory (according to the ASTM 105.05a )».ELYCOLD laminates are characterised by a poly-merisation at room temperature which, by avoi-ding the thermal shock typical of the conti-

nuous process, allows for a perfect level of pla-narity to be reached, a characteristic which isindispensable for the production of panels of avery high quality and of excellent aestheticeffect. Gelcoat resins, minimal shrinkage, low instyrene, but highly resistant to ultraviolet rays,are used in high quantities. The RV’s manufacturers that need longer coilscan choose ELYPLAN, Brianza Plastica’s coilableproduct, up to 700' of length and best-sellinglaminate for the roofs. ELYPLAN is a continuousfiberglass laminate and its high quality is gua-ranteed through the use of quality raw mate-rials and of a gelcoat obtained from very elasticisophtalic resin, which ensures resistance to yel-lowing, waterproofness from water vapour andcondensation. ELYPLAN is available in rolls of amaximum width of 10.5 ft, lenght on requestand plates cut to measure.

Brianza Plastica has also developed ELYPLAN HF(High Finish), a laminate in continuous manu-factured using "chopped strand mat" forgiving the best aesthetic finish, ideal for theoutside walls and for HOT-MELT laminationsystem. RV’s manufacturers that want to repla-ce the combination of LUAN + FRP or simplywant to save weight on the panels, can chooseELYCOLD LITE and ELYCOLD XLITE. These lami-nates containing microspheres, are very thickand are obtained by reinforcement of glassfabric based on an ultra-new concept. Theystart from 0.060" and reach high thicknessesup to 0.16”.

B rianza Plastica was set up in1962 to produce fibreglass

laminates. Over time, it has signifi-cantly extended its market presencewith a comprehensive productrange. It has served the constructionindustry from day one and has beenenjoying increasing success in thetransport sector since 2006. In thisarena, it supplies fibreglass sheetsboth to manufacturers of recreatio-nal vehicles (campers and caravans)and to lorry and refrigerated-trailerproducers. The company is based inCarate Brianza (just north of Milan),with other factories in Ferrandina(near Matera), Ostellato (nearFerrara) and San Martino diVenezze (near Rovigo). It has stora-ge facilities in Nola (near Naples),Lyon (France) and Elkhart (USA).Brianza Plastica is the Europe’s lar-gest producer of fibreglass. It makeslaminates both with continuous hotand with discontinuous cold techno-logy.

Company Profile

Paolo and Alberto Crippa.Brianza Plastica CEO.

12

The standard kit is for everyoneCBE doesn’t just supply large camper manufacturers: it also caters to smaller outfitters, offering standard modularsolutions that are designed to satisfy every need, even in terms of price.

CBE Srl - Via Vienna, 4 - z.i. Spini (settore D) - 38121 Trento - ItalyTel: +39 0461 958381 - Fax: +39 0461 960009

E-mail: [email protected] - Web: www.cbe.it

An Italian company with almost 40years of history, CBE supplies overtwo-thirds of all premium vehicle

manufacturers, with a leadership position inthe mid to high range section of the market.This specialization in the premium segmentallows CBE to develop innovative and reliableproducts bearing high quality standards. CBEhas transferred this know-how to the rest ofits production and to the standard modularkits available for any motorhome builder.Thus, even smaller manufacturers can benefitfrom CBE’s experience, with a broad range ofsolutions to choose from for all their needs.Furthermore, buying directly from CBE, i.e.directly from the manufacturer, avoids havingto pass through the supply chain, with manyadvantages not just in terms of price. Indeed,

CBE - as a producer that designs, manufactu-res and markets its products throughout theglobe – provides directly to its customers itsvery own technical support and specializedconsultancy services. CBE standard solutionsare based on 2 different versions of its 12Vdistribution box (depending on the number ofmains to be connected), from 10 (DS300) to15 (DS520) circuits and can be combined witha wide range of CBE control panels, from thewell-known PC100 to the all-new PC380.“What sometimes concerns smaller manufac-turers is the belief that in order to supply themdirectly, CBE requires major volumes andwants to sell them the complete wiring har-ness as well,” explains Paolo Moiola, exportmanager at CBE. “However, this isn’t the waywe like working with smaller manufacturers,as we are well aware of the fact that it isalmost impossible to satisfy different needs onsmall batches of vehicles that are often verydifferent one from the other. In these cases,we supply only the cables connecting the 12Vdistribution box with our devices, i.e. typicallythe control panel, the water tank sensors andthe battery charger. Clearly, we also provideall of the connectors and terminals with thestandard kit, thus allowing manufacturers tointernally assemble the main wiring harnessto be connected to the distribution box.Moreover, we give our customers freedom ofchoice: for those who want to, it is f.e. possi-

ble to use battery chargers made by othermanufacturers. Of course, we’re always wil-ling to develop customized wiring systems onrequest, although the development of a mainwiring harness for just a few units can some-times come with higher costs than the poten-tial benefits for the customer.” CBE flagship product for this family of stan-dardized solutions is the DS300 12V distribu-tion box, which can be connected not only tothe renowned PC100, PC150, PC200 andPC220 panels, but also to the new PC180,PC380 and even to the all-new control panelsCBE is developing for the upcoming season.This feature allows customers to employ aninstallation based on a single 12V module that

BASIC

PC150

PC100 PC200

PC180

PREMIUM

PC380

DE LUXE

PC770

Words Giorgio Carpi

13

Contacts:Dorian Sosi - Italy - [email protected] Moiola - Export - [email protected]

can be combined with a variety of control panel models, from the mostbasic to the most complete. “Our customers are motorhome manufacturers producing from 20 to5,000 vehicles a year. Every year, we supply over 1000 standard kits todozens of small manufacturers throughout the world,” continuesPaolo Moiola. “The designs, research and development we’ve workedon in recent years for our international customers allow us to offereven to our minor customers a degree of experience that our compe-titors couldn’t easily match. In addition, we would like to emphasizethat CBE is a partner that doesn’t leave its products aside once paid bya customer. Taking a look back over the past 15 years, we know thatour components have been fitted into over 350.000 motorhomes andwe will naturally continue to provide tech support a nd consulting evenfor our older products.

Premiered at the Caravan Salon in Düsseldorf 2014as a design concept, the PC210 is the latest inno-vation in the large family of CBE control panels.

Designed to be installed also on vans, where the availablespace between the cell door and the roof is limited, thePC210 features a contemporary design that recalls thelatest hi-tech trends, in terms of both styling and mate-rials. A control panel that combines compact dimensionsand a significant technology content at an attractive price:a custom backlit LCD 3” display in 13 different colours,with touch capacitive switches, a visible thickness of just9 mm and an innovative fastening system. The PC210 willbe customizable in many different ways and will be avai-lable as of mid 2015, giving CBE’s OEM customers theopportunity of opting for an additional newly conceivedcontrol panel, without having to make any changes to therest of the basic electrical system.

A QUICK LOOK AT A NEW ACE IN THE HOLE

DS300The DS300 12V distributionbox features 10 circuits protec-ted by fuses and is compatiblewith the control panels of thefollowing lines: Basic (PC100, PC150, PC180,PC200,)Premium (PC220, PC320,PC380)DeLuxe (PC770)

DS520The DS520 12V distributionbox features 10 circuits pro-tected by fuses and is com-patible with the controlpanels of the followinglines: Basic (PC 200)Premium (PC220, PC320,PC380)DeLuxe (PC770)

Booth at Salone del Camper in Parma

Booth at Caravan Salon Düsseldorf

CTA doesn't just interpret evolution,we define it. An industry leaderwith over 30 years' experience in

the automotive sector, specializing in themanufacture of seat belt anchoringsystems on board recreational vehicles,swivel seat paddles and TV stands. CTA is an Italian based company that pro-poses innovative solutions, with high qua-

lity products that make use of the latesttechnology for RV manufacturers and end-users alike. This is the case, for instance,for the Truma Combi Ready, a seat beltstructure that houses the Combi modelheater within it. In addition to optimizingspace and freeing up storage compar-tments, the heater can be installed in acentral location with respect to the vehi-cle's layout, thereby optimizing ductedwarm air distribution.

14

CTA Srl - Via Groenlandia, 23 - 00040 Pomezia (RM) - ItalyTel: +39.06 91601096 - Fax: +39.06 91601096

E-Mail: [email protected] - Web: www.ctapomezia.it

Performing and speeding up evolutionIn order to respect R14 and R17 regulations which came into force on November 1st, CTA has updated itsproducts, in collaboration with TÜV Rheinland: following the revolving paddles, the seat belt anchoringsystems now also comply with the new directives.


Dario Bellezze

Booth at Caravan Salon Düsseldorf

15

Contacts:Dario Bellezze - Sales Manager [email protected]

November 1st 2014 is the com-pliance deadline for the imple-mentation of the new R14 andR17 regulations. The new R14regulation stipulates that revol-ving paddles and seat beltanchoring systems must bemodified. Whereas for revol-ving paddles this does notentail any structural variations,for anchoring systems, on theother hand, CTA has developedthe integrated “Isofix” seat,designing a unified structurethat can be used with either auniversal or semi-universalseat. CTA has updated all itsproducts to respect theEuropean directives, in collabo-ration with one of Europe'smost authoritative certificationbodies, TÜV Rheinland, thesame service used by leadingautomotive manufacturers in

Germany. This allows vehiclemanufacturers to state thatthey are fully compliant withthe directives, mounting com-ponents that comply with thenew standards. The elementstested are modular designedsystems that can be installedduring the vehicle's construc-tion, both on existing and basicstructures.“Someone recently said thatour pay-off 'Performing theevolution' is a little pretentiousfor a company specializing inmetal working,” says DarioBellezze, general manager ofCTA.“Well, we've always demon-strated with facts that we're aninnovative company thatinvests a great deal of resour-ces in research and develop-ment, providing innovationeven in a sector where somedistracted observers feel that

everything has already beeninvented.” CTA anchoring systems can bemounted onto any type of RV(vans, motorhomes, semi-inte-grated, rooftops) in the M1 /N2 category. Easy to install,CTA structures only require theboring of two holes on thecabin floor, with fasteningbolts (threaded rods) and brac-kets to the frame side mem-bers. For vehicles with a gapbetween the cab and cabinfloor, the structures are sup-plied in two different heightsettings in order to adapt tothe dinette.“Right from our entry into thecaravanning sector, we set our-selves the goal of developingnew technological solutions,”adds Dario Bellezze, “that alsoaim to contain weight con-straints, and provide installa-tion simplicity and facility.”

F ounded in 1977, CTA currently supplies major Italianand European RV manufacturers, designing and pro-

ducing seat belt anchoring systems, swivel paddles, TVstands, ladders and roof racks on board recreational vehi-cles that are fully compliant with all European regulatorystandards enforced. A wealth of experience and anexceptional management organization have led to rapidproduction development. CTA is also a design partner formanufacturers of campers and caravans, making availa-ble its know-how and working alongside engineeringdepartments to find solutions for every need.

Company Profile

Isofix with Inglesina

Relax Seat System

Truma Combi Ready

16

FAP Srl - Via A. Gentileschi, 40/9 50142 Firenze (FI) - ItalyTel. +39 0557331750 - Fax +39 0557331758

E-mail: [email protected] - Web: www.fapweb.it

The high level of interest at the fair in Düsseldorf for the new locks must notovershadow the other successful products of FAP, especially the diversifiedOrus Line.

A path to success in the world

A fter the huge event represented bythe Caravan Salon in Düsseldorf, forFAP it is time to take stock: the

Florentine company, founded in 1968 and thelong-standing partner of major European andnon-European manufacturers of recreationalvehicles, has not only maintained its presencein the field but has continually expanded itsrange and developed a growing interest inthe caravan industry, and its product catalo-gue now includes seven different categories.“Our production – explains Lapo Ermini,grandson of the founder and current CEO ofFAP – began nearly fifty years ago with anaerator, a simple piece of moulded plastic,and it continues today with technically advan-ced locks like the one just presented at thefair in Düsseldorf. It is a lock with a servo-assi-sted locking mechanism designed for those

seeking top quality access doors on their cam-per.” The new lock derives from the nowwell-known Ghost locking mechanism withone or even two locking points, the pride andjoy of FAP products. Conceptually similar toautomobile locks, it goes even further byincorporating an automated locking system.A state of the art lock, therefore, which catersin no uncertain terms to high-end vehiclesand offers ease of closure and extreme noisereduction. “At the Caravan Salon in Düsseldorf – conti-nues Lapo Ermini – the new automated loc-king mechanism was appreciated by all theexperts who came to visit us at our stand. Iam pleased to say that soon, presumably inFebruary, we will begin series production forour first customers in Italy, France andGermany. I think it is important, however, to

repeat that our success in the lock sector hasin no way overshadowed the productionvolumes and sales of our other products. Thisperformance was achieved thanks to both anongoing study carried out by our designers toimprove and innovate our products, andthrough the investments we have made andcontinue to allocate in order to provide high-level tech support, with a constant commit-ment to customer follow-up after the sale.”But what are these products? Very often, theyare technical elements of small dimensions,sometimes barely visible, but which oftenhave key roles on recreational vehicles. This isthe case, for example, of the Orus Line, whichincludes fillers and external inlets mounted onthe side of campers and caravans. This line ischaracterized not only by a modern andattractive design, but also by the interesting

Ghost with the new automated lockingmechanism

Words Giorgio Carpi

family feeling assured by a common aestheticthat brings a certain elegance and visual con-tinuity to any modern recreational vehicle. Thecustomer – that is to say the manufacturer ofthe vehicle – is given the opportunity to choo-se the colour of the frame and the cap, andthe variety of colours available can become adistinguishing element of the vehicle’s sideand can often match the graphics alreadyselected for use. The Orus Line series, whichstarting this year will be exported to Australia,too, includes external inlets for connectingthe gas supply, a quick connection for water(with a pressure reducer and check valve), butalso the quick connector for the outdoor sho-wer, the external 230-V/16-A power supplyand a multifunction plate that includes the12-V socket, the 220-V Schuko socket andthe sockets for the digital terrestrial and satel-lite antenna cables. The ease of installationand the ability, in case of damage, to replacethe cover lid quickly and easily with replace-ments sold in the after market are features

that should notbe underestima-ted. “Since its launchon the market –explains LapoErmini – the OrusLine has seen asteady increase insales and its suc-

cess is well establishedin Italy and France, and next

year should extend to Germany aswell. This is thanks to features that

make our fillers unique: consider for examplethe automobile-style friction cap for both thewater tanks (including supplementary tanks)and for the diesel fuel tank. And as for thefuel-tank filler, our catalogue also contains theadapter for the original Fiat cap, which isimportant for motorhome builders: originalsecurity certificates regarding vehicle overtur-ning can be maintained, thus saving moneyon additional certifications.”Other historic products in the FAP range inclu-de the discharge valves of the grey watertanks. In this case there has been a significantevolution of the product’s method of assem-bly: the bonding system has in fact beenabandoned and the components are now joi-ned by electrical welding. This method ensu-res strength, reliability and guarantees absolu-te impermeability.Another product that is small in size butessential for the proper functioning of cam-ping vehicles of the latest generation is themagnetic lock for the doors to bathrooms andclosets:

17

Contact:Lapo Ermini - General [email protected]

This article was presented at lastyear’s Caravan Salon and cansmoothly enter all markets and

play an important role in the produc-tion of furnishings for recreationalvehicles within and outside of Europe.The magnet placed inside the lock –on the lock plate positioned on thedoor frame – is able to pull the latchtowards itself, which guarantees anextraordinarily silent mechanism. Thislock is easy to install and can be usedwith all the handles on the market. Itis not only silent, but is also extreme-ly flexible in use. It can be installed onsimple one-panel doors, but can beused also with multifunctional doors,which are becoming increasinglycommon on campers of recent design– doors that are used to close boththe toilet compartment and the slee-ping area – at the user’s discretion. Inthis case, the manufacturer must sim-ply mount a second lock plate.It is thus clear then that FAP is com-mitted to 360-degree design, withthe specific goal of meeting custo-mers’ needs both with universal pro-ducts and with personalized items.And this, combined with considerableattention to after-sales service, hasenabled the Florentine company to gobeyond not only its own national bor-ders, but also those of Europe, and isnow present in Australia, and since acouple of years ago, on the extremelyimportant market of the UnitedStates.Company Profile

F or almost half a century FAP has been a manufacturer ofplastic components. The founder began to approach the

camping industry in 1968 at the urging of two entrepreneurswho have made history in the Italian caravan market, LuanoNiccolai of Rimor and Giovanbattista Moscardini of Laika. In1982, the company began producing for the railway industry,where it maintains its presence by supplying furnishing com-ponents for railway cars. The company headquarters, whichincludes the technical office, production line and warehouse,is located in Florence and covers an area of 4,000 square

metres. With the production of locks for campers and cara-vans, FAP has long since achieved a leading position inEurope, covering 80% of the market and working both withvehicle manufacturers and with the most successful manufac-turers of doors and hatches. In 2011 the company launchedthe Ghost lock, the top of the line and a real benchmark inthe industry, with a mechanism capable of handling two loc-king points. In 2014 the evolution of Ghost was presented,and the lock is now equipped with a servo-assisted lockingmechanism.

Magneto

FAP booth at Düsseldorf Caravan Salon

1818

Filippi Legnami S.P.A - Via N. Sauro, 2 - 24030 Berbenno (BG) - ItalyTel. +39 035 861122 - Fax +39 035 860190

E-mail: [email protected] - Web: www.filippilegnami.com

Melamine for the RV sector

W ood has always been an essential component of recreatio-nal vehicle cabins - not just a fanciful designer whim, butan indispensable element. Experiments have been conduc-

ted to go beyond wood panelling, but in the end tradition has alwayswon out, as wood has proven to be an age-old material that like noother provides the necessary warmth and ambiance sought by camperand caravan users everywhere. However, this doesn’t mean things are-n’t progressing: many changes have been implemented over the years,from both a technical and cabin design perspective. At Filippi Legnami,the latest innovation developments have occurred specifically to crea-te products using state-of-the-art technology, heralding new trendsthat not only accommodate changes, but also pre-empt new ideas,while imagining new scenarios. For over forty years, Filippi Legnami’score business has always been woodworking, and the camper andcaravanning sector has provided a new challenge. In just a few years,our broad product range in this segment has allowed us to become anindustry leader. Since 2013, the newly formed partnership betweenFilippi Legnami and Giorgio Levoni, a managing partner and entrepre-neur from the renowned family operating in the food industry, hasresulted in an even stronger presence in the sector, creating newsynergies for innovation and the deveopment of processes and pro-ducts.

Consolidated production and digital printingFilippi Legnami specializes in the finishing of wood based panels. Thisis a well-known, consolidated process in which decorative paper isapplied onto the surface of a panel used for cabinets, wall units,doors, etc., built in wood in a recreational vehicle. Various types ofdecorative film are used, such as finish paper, PVC, PP, CPL or Alkorcell.The finishing material is applied onto plywood or multi-layer panels,ranging in thickness from 1.8 to 4 mm, by a pressing and cementingprocess, using a latest generation calendar press.Since 2013, Filippi Legnami has offered its customers digital printingon decorative paper used to finish wood panels. Two hi-tech plottersare used to print any pattern or texture, either from Filippi Legnami’svast catalogue or from unique solutions created by the customer’sown designers, faithfully reprodu-cing any motif provided by the custo-mer. This allows for an extremelyhigh level of personalization, availa-ble not just for high-volume orders,but also for limited productions fromsmall upholsterers or the increasinglypopular limited series of large manu-facturers. The scale can also be


For years now, Filippi Legnami has been a trusted supplier for many camper and caravan manufacturers,and has recently expanded its product range: alongside the popular and traditional wood veneer panelproduction, new digital printing machinery have recently been introduced, as well as a novel finishingsystem for melamine paper multilayer panels.

1919

Contacts:Francesca [email protected]

E stablished over forty years ago and specializing in theprocessing of wood products, Filippi Legnami decisively

entered the recreational vehicle sector in 2000, introducing aline of finishing products. Finished panels created by FilippiLegnami have been used for an endless array of applicationsin the cabins of campers, caravans and mobile homes, adop-ted by manufacturers worldwide. In 2013, the partnershipwith entrepreneur Giorgio Levoni opened up a fresh phaseof consolidation and expansion. Initiatives have included thelaunch of a new product range employing digital printing forpersonalized panel decoration. Recently, a new departmentwas introduced with a panel pressing line using melaminepaper: making use of sophisticated advanced technology,Filippi Legnami provides 3D effect surface linings that combi-ne an innovative tactile experience with high resistance toabrasion, scratches, wear and light.

Company Profile

varied, i.e. reproducing the same pattern indifferent sizes, adapting to different types ofpanels, whether cabinet doors or small dra-wers.

The new frontier: melamineInvestments in research and development areongoing, with the recent introduction of aspecial press for finishing panels with melami-ne paper.“We’re currently the only suppliers in thecamper sector to have applied melaminetechnology to plywood,” explains SalvatoreFilippi. “Melamine is a system used for homefurnishings, where it is combined with chipbo-ard. Applying this technology to multilayerpanels today places us at the forefront of ourindustry. Using our new melamine press, weneed to find the right balance between heatand pressure, but once an optimal balancehas been found the possibilities are trulyendless. Today, we’re capable of offering ourcustomers an infinite range of finishes andcustomizations.” Applying home furnishingtechnology to the camper sector has allowed

Filippi Legnami to meet the most diverseneeds of customers, creating effects that wereunthinkable until now. Just how does thissystem work? Very thin sheets of decorativepaper, impregnated in melamine resin, areheat pressed onto wooden panels, in this caseplywood. The addition of special overlays,special additional sheets placed onto thepaper, can confer an unlimited array of cha-racteristics to the surface: e.g. scratch-proofor fingerprint-proof overlays, soft touch over-lays, glossy effect overlays – the range is trulyendless. However, the most innovative charac-teristic of this technology is the three-dimen-sional finish plating. A steel mould is insertedin the press which contains an embossed pat-tern. The end result is thus no longer just asmooth two-dimensional panel, but can fea-ture embossed or raised motifs, for instancecreating a real wood effect, complete with anembossed grain, knots and imperfections.There are essentially no limits to a designer’screativity, so that the level of customization isreally endless.“Various types of applications are possible,”

says Salvatore Filippi, “and we’re not just thin-king about cabinet doors and wall units.Indeed, we can create more resistant wallpanels, with extremely wear-proof characteri-stics. At the customer’s specific request, wecan even create water-proof or fire-proof wallpanels, providing various degrees of protec-tion. And we can also work on floors, usingmelamine to create wear and scratch resistantwood flooring with special embossed or rai-sed motifs. We can achieve a very high level ofcustomization, and it isn’t difficult to produceat a sustainable price for a manufacturer a‘special edition’ for a unique customized fur-nishing, even with personalized lettering. Digital printing and melamine open up newfrontiers for the customization of furniture.Customers can choose from an infinite rangeof ‘bespoke’ products, a combination of grea-ter freedom of expression on the part of desi-gners, and the use of the most sophisticatedtechnologies. End users can now rely on furnishings createdwith originality and craftsmanship that arealso more durable.

Booth at Düsseldorf Caravan Salon

20

Metallarte Srl - Loc. Rigoni - Via dei Laghi - 53035 Monteriggioni (SI) - ItalyPh. +39 0577 306 163 - Fax +39 0577 304 461

E-mail: [email protected] - Web: www.metallarte.com

America opens its doors to Metallarte,but we could also say that it will openMetallarte’s doors: this is not just a play

on words because it sums up the long andmeticulous effort that has enabled the Italiancompany to look out across the ocean, wherea huge market might be extremely interestedin the doors realised by the Italian manufactu-rer. Moreover, years of experience on theEuropean market have built a solid foundationand a body of technical-productive knowledgethat can become a springboard for crossing theAtlantic and working in a geographic areawhere the culture of living on the road is wellstratified. But what can a small business likeMetallarte offer the American giants of theindustry?“It’s true, we are a small to medium sized com-pany – explains Michele Checcucci, CEO ofMetallarte – but perhaps this is our greatestasset and what sets us apart from other largercompanies and allows us to stand out in a sec-tor that is already pretty crowded. It can be saidthat our flexibility in production and responsi-

veness to customer needs are the qualitiesappreciated most by vehicle manufacturers,with whom we have maintained contact on adaily basis for years. We work quickly and weneed only a few days to draw up a completeproject that conforms to the client’s requests,and in a month or even less we can alreadydeliver the finished product. We can standardi-ze production, but we can also deviate fromthe standard without difficulty in order tochange the product, customise it and adapt itto new needs. And camper doors – the entrydoors to the living area – can benefit from ourdynamic approach, especially in a market asimportant and challenging as North America.”The goal of Metallarte is to provide Americanmanufacturers with a product that is substan-tially different from what they are accustomedto; this is the only way to compete with localcomponent producers. Design is anotherimportant trump card. Italian Style continues to

be a winning feature, but of course it is notenough just to export doors that are beautifulto look at, it takes something more. The doorsof European conception have some interestingfeatures that will be perceived as new by theAmerican customer. Just to give one example,think of door panels equipped with pocketsand containers, but also with a trash basket, oreven different bins for recycling.“I think product customization is a strategicweapon – continues Michael Checcucci – acard that we can and should play on theAmerican market. We are able to offer thecustomer several variants to a standard modeland they can then transform the door into aproduct that is totally different from the basemodel. The client, for example, can choose theinner finish of the door, the one inside the vehi-cle: we have our own range of thermoformedfinishes, but we can also custom design a finishand realise a mould made for a specific custo-

A quality-oriented policyAfter its recent presentation of a larger, wider door, the dynamic Tuscan company is working on several ambi-tious projects and is now looking to enter the American market.

FIPFG (formed-in-place foam gasket)“Gasketing” is a process that involves the production of gaskets foamed directly

onto components by using a FIPFG (formed-in-place foam gasket) sealing system.This system consists of a base component and a hardener, mixed in specific propor-

tions. This method generates a gasket in soft polyurethane foam in just a few minutes.After the polymerization is complete, the gasket is dry to the touch and the piece can beassembled. The application of this technology to the doors and the aluminium profilesused in the production of doors and hatches in the RV industry was patented byMetallarte, which had already been granted a patent for its vacuum mounting system.One of the specific machines in the FIPFG process deposits a layer of liquid polyurethaneon the inside of the aluminium frame. This substance solidifies in a short time and main-tains a high degree of compressibility and impermeability, then becoming the anti-infil-tration gasket interposed between the sandwich panel and the frame. The sandwichpanel is placed on the assembly bench and is placed on the frame. Here a pump createsa vacuum and allows the panel to adhere perfectly to the gasket. The whole piece is thenassembled by means of small metal plates fastened with rivets fitted with O-rings.

Michele Checcucci, General Manager

A frame made entirely of plastic (prototype)


mer, to ensure that he and he alone is theowner of that kind of door.” Continuing onthe subject of doors, the new XL door ofMetallarte was presented at the Caravan Salonin Düsseldorf and it will be fitted first on certainmodels of Adria vehicles. It represents the evo-lution of the classic two-locking-point doorsalready in the catalogue: the door XL abandonsthe standard width of 580 mm and offers agenerous opening of 650 mm. Wider doors area constantly growing trend in Europe.Manufacturers are trying to cater to thosewho, either because of their physical size orbecause they are no longer as young as theyonce were, are uncomfortable trying to squee-ze into a door that is only about 55 wide. Therealization of a maxi-door poses no technicalproblems – the only downside, if any, is thesmall reduction in space for the kitchen orother furnishings.Metallarte is also investing seriously in thecabin doors of motorhomes. The project is

already at an advanced stage and the productline should be on the market by the end of2015. The company’s intentions are not to pro-pose another standard door like so manyothers already on the market, but to aim forexcellence. The project is challenging andcostly, for sure, but the motorhome segment ispromising and so Metallarte is not afraid toinvest.As further proof that there is no shortage ofideas and vitality in the Tuscan company, herecomes an anticipation of a project still in themaking. “Together with the University ofFlorence, we are moving forward with a veryinteresting and innovative project – explainsthe CEO of Metallarte – and it could see thelight in 2016. The idea is to realize a closingdoor to storage compartments made entirelyof plastic, like some that already exist, but amodular one that has greater flexibility in sizecompared to traditional doors. We still have toperform some tests – of the rigidity of thematerial and the resistance to the sun, for

example – but I am confident. In any case, wehave already patented the system.” As you canguess, the desire for achievement is strong inthis small but resourceful company, whoseheadquarters are near Siena, in the area ofTuscany where most of the industries of theItalian caravanning sector are located.Metallarte is a company whose mission is in itsname: metalworking, aluminium in particular,makes it possible to create objects in a precise,workmanlike manner, according to the formschosen by the customer; not only doors andcompartment lids, but also profiles uniting theroof and side of the vehicle, side skirts, internaland external stairs, basically anything that canbe created to make recreational vehicles morefunctional and aesthetically valuable.

Company ProfileM etallarte is a company with

nearly 20 years of history, certi-fied UNI EN ISO 9001:2000. The com-pany’s mission is to be among the lea-ders in Europe in meeting the needsof the recreational vehicle compo-nents and equipment market. It seeksto contribute to improving the quali-ty of life in your spare time by offe-ring constantly new solutions and ser-vices. And the company’s vision is veryambitious, too: a Metallarte productfor every camper in the world. Withits range of complete doors, hatchesand other products for the OEM mar-ket, Metallarte today is supplier tothe principal manufacturers of recrea-tional vehicles: the brands of theFrench groups Trigano, Sea andRapido; the Slovenian brand Adria;almost all the Italian brands, Laikaabove all; Auto Trail in the UK and afew manufacturers in Australia andNew Zealand. The manufacturing plant, which hasrecently been reorganized to meetevolving needs and increased produc-tion volumes, is centred around a2700-square-metre building equippedwith a 277 kWp photovoltaic systemproducing 100% green energy.

Contacts:Michele Checcucci - General [email protected]

Metallarte booth at Düsseldorf Caravan Salon

21

22

Via A.Vivaldi, 40/A - 50041 Calenzano – (FI) – ItalyTel: +39 055 8825239 - Fax: +39 055 8878086

E-mail: [email protected] - Web: www.project-2000.it

Good ideas that “move” RV’sFrom its first success with retractable steps, Project 2000 has expanded its horizonsand now offers a range of systems to make the furnishings in recreational vehiclesmovable in a practical fashion.

W hen speaking of a compa-ny likeProject 2000,

the term “growth” ari-ses spontaneously. Greatstrides have been madesince the end of the 90swhen the small companyfirst entered the camperindustry with its own produc-tion of steps. Today one canrightly speak of a well-structured,international business that still operatesexclusively in the recreational vehicles sector,but now produces more than just steps, with arange of products in various areas. In recent years, despite the pre-vailing crisis, growth has been very solid – so much so that theowners have decided to create a new profession position, that ofinternal sales manager, who will take over the tasks previously per-

formed by an external agency representing several firms. The newtechnical sales manager, Lorenzo Manni, has been with the com-pany for a couple of years and has a degree in international

relations and past experience with the Siemens group,where he not only developed his sales skills, but

was also able to gain valuable technicalskills. With the creation of theinternal sales division, greaterresources have been allocatednot only to customer mana-gement and the search for

new markets, but also to mar-keting and communication.

“Implementation in the sales divi-sion was a challenge – Manni himself tells

us – but the results are very encouraging. Our entry into theAmerican market was the first step, perhaps the most important.and it was a smashing success. In just a year and a half NorthAmerica has become an important market for us. With the adventof new business strategies and a methodical search for the rightpartner, there has been truly significant growth. Moreover, wehave registered remarkable growth in Australia, too, strengtheningour relationship with the leading manufacturer there and layingthe basis for the opening of a local distribution channel.”And if non-European markets represent the new challenge ofProject 2000, China certainly cannot be overlooked: the numbersare still low, but the growth rate of the last turnover bodes well forthe future. Despite the inevitable difficulties due to the languagebarrier, we have completed a commercial tour there that has ena-bled us to know our customers much better. A different relation-ship with the local distributor was definitely created: no longer justa simple response to customer needs, we will now have a boosttowards expanding the market. America, Asia and Australia in growth, therefore: but what aboutthe relationship with European manufacturers? “The development of faraway markets certainly did not force us toneglect Europe – continues Lorenzo Manni – where we continueto gather the fruits of our efforts in research and development,which have led to our working with virtually all major manufactu-rers. France, Germany and Italy, of course, are giving us great

Lessons from overseas

I ncreasingly committed to proper training of the client-installer, Project 2000 has organized several technicalcourses at the manufacturers’ work sites in order to

train the staff responsible for tech support of its products.After the positive results obtained in Europe, for example inthe Laika and Carthago factories, a training course in theUnited States has now been scheduled in conjunction withthe Louisville RV Trade Show sponsored by the local distri-butor Lippert Inc. On that occasion, all the American manu-facturers who want to install a Project 2000 electric bed willhave the opportunity to speak with representatives of boththe company and the distributor and ask specific questions.The operation of the bed will be explained in a classroomsetting and explanations will be given about the structureand design of the product. A troubleshooting module is alsoscheduled in which concrete solutions to the most commonpractical problems will be given.


Lorenzo ManniTechnical Sales Manager

23

Contacts:Davide Nardini - [email protected] Manni - [email protected]

To meet the increasing demand fortables with a central support – notanchored to the wall – Project 2000

has presented a novel prototype of tele-scopic leg designed for high-end and tra-ditional motorhomes. Encouraged by thepositive response of visitors to the recentCaravan Salon in Düsseldorf, it will go intoproduction very soon. It is a telescopic sup-port in aluminium profiles with three tele-scopic sections equipped with an electricmechanical movement activated at thetouch of a button. The motorizationmakes use of a special device that ensureshomogeneous extension of all the ele-ments at a speed of 18 millimetres persecond. The weight is limited to about 6kg, it has excellent stability and a loadcapacity of 60 kg. There are several defi-

ning elements that distinguish this pro-duct. First of all, the support can be moun-ted right-side-up or upside-down – that iswith the slightly pyramidal shape inverted– at the discretion of the vehicle manufac-turer, so as to vary the final design of thetable according to taste. The motor is fullyintegrated in the aluminium profiles, sonothing protrudes from the telescopic legand there is no need to create holes in thefloor. The manufacturer may choose whe-ther to anchor the table in the traditionalway, with a plate protruding above thefloor, or with a hidden plate, with the legresting directly on the floor. A complexmechanism that allows the table to bemoved sideways and rotated can be wellfastened above the telescopic leg, therebymeeting the needs of those having a meal

in the dinette, but also facilitating themovement of the crew around the tableand, last but not least, making transit fromthe cabin to the passenger compartmenteasier. Worth noting is the single point ofrelease of the shifting mechanism, withoutthe traditional double or triple safetystops.

rewards, thanks mainly to adjustable-heightbeds, whose market trend is one of conti-

nuous growth.” Today the drop-down bed repre-

sents a sector of primaryimportance for us, not onlydue to the strong increase in

sales in recent years – which prom-pted the company’s expansion into the

American market – but also for the evolu-tion of the product itself, which is now anchored to the base andthe drop-down structure directly by Project 2000. This strategicstep forward has cured more than just a few headaches for manymanufacturers: now the bed comes already assembled and packa-ged, and only has to be anchored to the wall and ceiling. And speaking of beds, a “3-in-1” multi-function bed has also beencreated to meet the rising demand for rear central beds. It is a bedwhose base is lifted by gas springs (in order to access a storagecompartment below) and it slides longitudinally on bearings inorder to raise the headboard (to increase the space around the bedand for reading). There is also a lifting system (manual or electric)to vary the height of the garage realized under the base of the beditself. The product is unique in the industry, and at the 2013 edi-tion of the Salone del Camper of Parma – the Italian trade show

for the industry – it was given an award by a jury of experts. But the original mission of Project 2000 has not been forgotten,quite the contrary: this year our line of single steps has been com-pletely redesigned and now offers a wider range of choices. Thegoal is to improve overall quality, lightness and production efficien-cy: three objectives with which Project 2000 aims to obtain impor-tant recognition from the market.To support these important chan-ges, even the factory has been modified, which obviously mean aninvestment of capital, as confirmed by Lorenzo Manni.“The significant increase in production – concludes the salesmanager of Project 2000 – has made necessary a complete revi-sion of the warehouse and assemblylines in order to improve productionefficiency. Three automated verticalwarehouses have been realized, allinterfaced with a management pro-gram, so that operators are able tolocate the material quickly, withoutoverlapping and interfering with other employees.” And given theimportance that adjustable-height beds have in the overall budgetof the company, a special department for the assembly of bases,structures and lifting mechanisms has been developed. Onceassembly has been completed, the beds are packaged and tran-sferred to the shipping department.

Telescopic and motorized

Project 2000 booth at Düsseldorf Caravan Salon

24

Solera-Thermoform Group Spa - Via Cavalieri di Malta, 23 35038 Torreglia (PD) - Italy

Ph: +39 0499998811 - Fax: +39 0499998828 - www.soltherm-group.com

A Group that invests in the futureThermoforming Plastics is the speciality of the companies of the Solera-Thermoform Group.Automated and cutting edge production processes and innovative solutions for combiningdissimilar materials are the challenges of the future, even for the RV sector.

In an industry reluctant to change such asthat of recreational vehicles, new thermo-form techniques and moulds have created

new scenarios. Thanks to new technologiessuch as Twin-Sheet Forming, it will now bepossible to implement more standardized pro-duction processes, with positive effects interms of quality and costs. This is the opinionof the management of the Solera-ThermoformGroup, a company with a leading position inthe field of industrial thermoforming of plasticswith applications in the area of recreationalvehicle that include rear panels, bumpers, roofmouldings, side mouldings, spoilers, toilets andinterior furnishings.

Forty years of thermoforming experience Thermoforming has always gone hand in handwith the production of motorized recreationalvehicles, especially since campers and motor-homes began to take on the characteristics of

an industrial product and were no longer cha-racterized by the craftsmanship of a singlevehicle. We can say that in some ways, theSolera-Thermoform Group was at the side ofItalian motorhome manufacturers ever sincethey began to market their first products.«Ours is a relatively young company, createdfive years ago – explains Riccardo Palatresi,managing director of the Solera-ThermoformGroup – but it was founded on the basis ofdecades of experience in the field of thermo-forming. The Solera-Thermoform Group, infact, is the result of the merger of two compe-ting companies that have made history in thisindustry. Thermoform was founded in 1976and has always worked with companies in thecaravan sector, supplying components for boththe exterior and the interior. Solera, which wasthen called Solera Materie Plastiche, begandoing business in 1974: it was then one ofLaika’s suppliers for the Motorpolo, one of themost innovative motorhomes of the day, and afew years later it supplied components for thenewly-born Rimor. These forty years representan extremely important technical and culturalsubstratum, but they are also a kind of sprin-gboard for future challenges. The SoleraThermoform Group was established with aview to increasing our market presence by sha-ring the know-how of the two companies, butwas also based on the willingness to invest andto innovate».The recreational vehicle industry is of funda-mental importance to the Group, thanks to asolid clientèle represented by the brands of theHymer, Trigano, Sea and Rapido groups. It is,however, no longer its sole business area.Infact, the crisis in the sector, especially in Italy,has prompted the company to expand anddiversify its activities and today SoleraThermoform Group is well established in otherareas such as agricultural machinery, industrialvehicles and buses.

The production processThe Solera-Thermoform Group can delivercomponents of different shapes, sizes andapplications, realized with vacuum thermofor-ming in lengths up to 4 metres, high pressurethermoforming and Twin-Sheet thermofor-ming. «For the recreational vehicle industry, thetechnique of thermoforming is interesting forseveral reasons – explains Michel Schmitz, mar-keting and export manager of the Solera-Thermoform Group – and it is competitive withother constructive techniques like fibreglass

Twin Sheet

In the manufacturing plant of Fucecchio, in Tuscany,production is carried out using the Twin-Sheet method.This is a particular method of thermoforming that

makes use of negative moulding, which makes it possibleto join two pieces so that they become integral already inthe processing stage, without the need for any subsequentbonding. This allows box-shaped elements to be produced that are highly resistant and lessthick than in the past. The hollow space inside the workpiece may, if necessary, be filled withfoamed material, perhaps as thermal insulation. The two pieces united in this way are moreresistant than those assembled by means of adhesives, have fewer risks and lower costs. Withthe Twin-Sheet technique it is possible to combine different materials, provided they are com-patible (for example ABS with methacrylate), even if they are of different colours.

Words Giorgio Carpi

Michel SchmitzMarketing & Export

Manager

25

Contact:Michel Schmitz - Marketing & Export [email protected]

layering or injection blow moulding. With thermoformingwe can realize very large pieces like the rear walls of

campers or certain front walls of motorhomes. Andwe do this with acceptable costs even for smallproductions, while injection moulding is veryexpensive and the costs cannot normally beborne by companies in the caravan industry.» Our two plants are equipped with next-genera-tion cutting and assembly systems, some ofwhich were designed and built to measure.Cutting is performed by computerised CNC mil-ling machines that can be programmed by usingsoftware compatible with the CAD platform, thusallowing a three-dimensional path to be program-

med. The assembly of the parts is then entrusted toa computerized system that applies the two-compo-

nent adhesive and bonds the pieces by placing them under apress. The real innovation of the cutting and joining systems is the crea-tion of an automated process that uses a robotic line, which by movingalong a track can manage four workstations in a sequential manner.Waiting times are thus eliminated, productivity is increased and costs arereduced. «Vacuum thermoforming is the most widely used method inthe RV industry as it requires fewer investments in moulds, providesexceptional design freedom, quick and easy prototype creation, islightweight, makes it easy to determine colour precisely, has rapid pro-duction cycles and offers the possibility of recycling – explains MichelSchmitz – but we can also offer high-pres-sure thermoforming to deliver extremelyhigh definition of the shapes and anglesor the innovative Twin-Sheet technique».The colour is defined at the origin by usingpre-coloured sheets; the sheet already hasits own brilliance, so subsequent polishing isnot necessary. Being able to reproduce a spe-cific colour exactly is an important feature,since it’s often necessary to match pieces to the colour of the body, forexample, or reproduce an identical colour scheme years after it was firstproduced.

New goals: the future lies between reality and possibilityThe technique of thermoforming is well-established and well-known tomanufacturers of motorhomes and caravans, but a lot can still be doneto renew production processes and achieve new goals. The latest salesfigures will have to be taken into account – and these have not beenrecord-breaking of late in Europe – and there must be a commitment toinvest. For its part, the Solera-Thermoform Group is making several inve-stments, as Riccardo Palatresi confirms: «Since the company was foun-ded we have invested heavily in equipment and research, and will con-tinue to do so. We are investing millions of Euros in the upgrading ofmachinery for thermoforming and in the expansion of our automatedcutting and assembly processes. Furthermore, the Twin-Sheet methodcould be successfully introduced into the world of motorhomes – affirmsRiccardo Palatresi – and dramatically change production processes andend products. If there were sufficient finances, the Twin-Sheet produc-tion process could be standardized and spoilers and front and back wallscould be realized. Many fibreglass elements present today on the vehi-cle could be replaced, as well as many of the interior furnishings, there-by reducing weight significantly, and thus the reduction of fuel consum-ption and CO2 emissions, in harmony with current European standards.I see standardization as the new goal of the RV industry, both for classi-cal thermoforming and for the Twin-Sheet method. Unfortunately, in thecaravan sector, not only is there little investment in research, but chan-ging fashions require rapid renewals of product lines and models, unli-ke the sector of agricultural and industrial vehicles and buses, where theproduct remains unchanged for 5-6 years. It is true that some detailschange, while others are kept for years. Standardization could be acce-lerated for these more permanent components by using thermoformingprocesses.»

Plastic-fabric combinationsBy means of thermoforming processes, the Solera-Termoform Group isable to unite fabric and plastic support materials directly in the proces-sing stage. The fabric is perfectly adherent to the underlying support,reproducing not only its general shape, but also detailed design featu-res. Currently, it is impossible to get similar results with traditional bon-ding methods. Plastic-fabric combinations have been tested succes-

sfully with success, for example in the creation of doors for fabric- covered wall cabinets.

Planning & DesignThe Solera Thermoform Group can count on in-house design capabili-ties and 2D and 3D design programmes. Its development of design andstyle also includes the construction of prototypes, which are realised inclose cooperation with its customers. This feature makes the companyunique in the industry and has contributed greatly to its success.

Solera-Thermoform Group was founded in late 2009 bythe merger of two important Italian producers, Solera

(formerly Solera Materie Plastiche) and Thermoform, whichsince the mid-70s have manufactured plastic materialsusing thermoforming processes The company has two pro-duction plants, one in Fucecchio, in Tuscany, and the otherin Torreglia Veneto. Being able to operate both with tradi-tional methods and with advanced systems, including theTwin-Sheet method and robotic lines, the SoleraThermoform Group is able to satisfy both small-scale andlarge-scale demands. Its primary relationship with therecreational vehicle industry, which has been such a largepart of the history of both Solera and of Thermoform, con-tinues today, but the company has now expanded its fieldof action to other areas: industrial vehicles, buses, agricul-tural machinery and “green cars” (electric vehicles to beused in urban settings). Orders are also received from therail sector, not to mention the parts produced for refrigera-tion systems and fitness-related machines, as well as manyitems for the Food & Drink industry (storage, distributionand packaging of food and beverages) and for the medicalapparatus sector.

Company Profile

26

Success in aftermarket......now the OEM segment

Sr Mecatronic has conquered major market shares in Europe, implementing a capillary sales and customersupport network. In the aftermarket segment, Sr Mecatronic products are recognized as among the very bestin terms of reliability, technology content and quality. It’s high time recreational vehicle manufacturers alsoconsidered this new player as a potential partner for their initial installations

SR Mecatronic Srl - Via Aldo Moro 1-3 - 40046 Porretta Terme - (BO) – ItalyTel: +39 0534 21477 - Fax: +39 0534 24075

E-Mail: [email protected] - web : www.srmecatronic.com

“We have a mature product that provides added valueto manufacturers who choose us for their initialinstallations. Customers who try out or satellite

systems never go back.” With these words, Marco Santoli, CEOof SR Mecatronic, invites Italian and global recreational vehi-cle manufacturers to consider one of his satellite dishes fortheir initial installations. A young brand name, havingbeen founded only in 2009, but one which has achievedan excellent reputation throughout Europe, thanks to itshigh production quality standards, a capillary and wellorganized sales and support network, and a wide pro-duct range to satisfy any need. SR Mecatronic satellite systems are proposed as a stan-

dard installation by Belgian manufactu-rer STX Motorhomes, a recogni-

zed brand at a European leveland among the most presti-gious outfitters of maximotorhomes in the premiummarket bracket. Belgium is

indeed one of the markets inwhich SR Mecatronic has grown exponentially,

attaining a leadership position in the aftermarketsegment as well. SR Mecatronic satellite

systems have been adopted as a standardfirst installation by the German manufactu-rer TSL, which outfits the luxuryLandsberg and Rockwood motorhomes,and are part of a package proposed at

the Düsseldorf Caravan Salon by AdriaGermany, on the new camper models produced by therenowned Slovenian brand.

SR Mecatronic has identified its models withvarious initials. For instance, 1P refers tosystems with just one factory-set satellite dishthat is monitored by a control unit with a singletouch key. Flat identifies satellite dishes with aclearance height of just 170 mm when closed,an extremely important factor for campers, notonly for aerodynamic reasons, but also to limitthe vehicle’s overall height. Plus identifies satel-lite dishes that incorporate a control panel thatallows for a choice of 15 memorized satellitepointings. The version with seven memorizedsatellite positions bears the name LED. The DFmodels feature an LNB with a dual output, i.e. they allow forthe simultaneous viewing of two different satellite channels.The Skew versions have a correction system for the LNB anglethat is entirely automated, using a GPS system for consistent

optimal reception,even at the marginsof the footprint. Inaddition, the Skewversions are equippedwith an automatic til-ting mechanism thatcorrects the satellitedish’s theoretical eleva-

tion angle with the cam-per’s actual tilt angle (e.g. if

the vehicle is on a slope oruneven parking lot). This function

incredibly enhances the satellite dish’s tracking capability, shor-tening the search time. The LNB angle can also be corrected onthe Prestige versions, although for these models it is performedusing a manual hand wheel.

Model specifications


ASR 850 FlatSkew Plus

27

“When we founded the com-pany six years ago, I neverwould have thought that wecould be so successful,” sta-tes Marco Santoli. “InBelgium, we’ve become mar-ket leaders. It seems like asmall market, but the num-bers are actually very signifi-cant. All of the big dealerswork solely with us, buyingour products almost exclusive-ly, since they’ve come to reali-ze the high value of our satellite systems,and our ability to provide quality and serviceat a competitive price. Professionals are notthe only ones who appreciate our satellitesystems. The public now request them too.Word of mouth among RV motorhomeenthusiasts is another of our strengths: oursatellite systems are exceptionally reliable,rarely presenting problems, and the fewcustomers who have had to call our tech ser-vice have received a quick and immediatereply with professional support, providing uswith excellent promotional feedback.”SR Mecatronic is present in Australia, NewZealand and throughout Europe (France,Spain, Belgium, Luxemburg, Holland,Switzerland, Austria, Germany, Great Britainand Sweden). In these countries, it has selec-ted exclusive, well organized distributorswho are capable of supplying customerswithin 24 hours. A B2B service and supportcenter was created for Europe, in Strasburg,where a decentralized warehouse is locatedwith spare parts and a helpline available tenhours a day including Saturdays, providingtechnical information for service centers inEnglish, French and German.The company’s goal is to build and imple-ment the best service and support networkin Europe in the satellite dish sector. InFrance, 16 service centers are already active,expanding to 25 within a few months.Service centers are already active inSwitzerland, Belgium, Holland, Spain andMorocco. In addition, in 2015 others willbecome operative in Germany and theUnited Kingdom. In Italy, where there are 25authorized service centers, the SRMecatronic Store project has also been intro-duced, with 40 out of 220 retailers in Italy onboard. Retailers taking part in the projectcommit to stocking the complete range ofSR Mecatronic products, including the“Mobile TV” LCD and “Avtex” television setsthe company distributes, so that customerscan get a close up view of different modelsof satellite systems. This formula is currentlyin its experimental phase in Spain as well. “Our service center staff have taken techni-cal training courses and have acquired thestandard support service kit. They can solvejust about any problem for customers travel-ling with their camper through Europe,” sta-tes Marco Santoli. “We’re really interested inbreaking through in the OEM market. Theaftermarket has recognized the value of our

products, and is rewarding us withincreased revenues that are approa-ching 40% per year. Most of theseearnings are coming from abroad,since we export almost 70% of ourproduction. Our satellite systems areextremely reliable, with warrantyreturns of less than 1% and a three-year warranty on all system compo-nents. We can satisfy specific needsfor an initial installation, providingwiring harnesses that are alreadysized for specific applications, and for

certain minimum quantities we even supplypre-assembled satellite dishes that can cutthe manufacturer’s installation time andcosts. We can thus create customized wiringharnesses, with racks housing a pre-assem-bled satellite dish. Manufacturer need onlyunpack the system and install it on board.We have unlimited production capacity, andwe’re capable of delivering all over Europe injust a few days’ time. In Australia and NewZealand, we ship by air in a week. And wekeep track of every phase of the productionprocess, because we assemble our productsin-house, and can therefore monitor the pro-

duction cycle entirely.” Lastly, with the newplanar satellite dish, SR Mecatronic has fur-ther expanded its range, to satisfy the needsof any customer type. The new ASR 500 FlatPlanar is a small satellite dish requiring verylittle clearance, at just 13 cm in height whenclosed: the lowest on the market today. It’sdesigned for users who have issues withheight, providing a solution against strongwinds, and can easily be mounted on theroof of a van, thanks to two assembly platesat the right distance to fit between the rib-bing on the roof of the van.

Contacts:Marco Santoli - General [email protected]

SR Mecatronic satellite systemsmake use of especially robustmechanical parts, featuring

powder coated die-cast aluminiumcomponents that are supported bya powerful motor. Moving compo-nents rotate on sturdy, quiet, fric-tion-free roller bearings. The LNBsupport, studs on the satellite dishsupport and the power adapter boxare built in anodized aluminum. Allthis guarantees a powerful motordrive, supported by carbonitrided hardened steel worm screws and bronze gear wheels,allowing for maintenance- free, perfect and stable satellite pointing over time. The elec-tronic board is protected against reverse polarity, power overloads and short circuits bymeans of a 5 amp blade fuse. The electronic board on board the unit is lacquered toprotect it against humidity, and the distribution box uses a four-layer printed circuitboard. The satellite system is equipped with a buzzer that warns the user if the satelli-te dish is open or turned on when the camper is powered on. Satellite searches are total-ly automated, using the DVB-S2 MP4 Full HD tuner, a high performance instrument thatprovides superior signal sensitivity in terms of transmission speed. An important featureis the search function, which memorizes the last position detected and thus reducessatellite time searching in subsequent uses.

ASR 500 Flat Planar

Marco Santoli

Booth at Caravan Salon DüsseldorfBooth at Salone del Camper in Parma

SR Mecatronic satellite system technology

28

Thetford BV - Nijverheidsweg 294870 AD Etten-Leur / The Netherlands

Ph: +31 765042200 - Fax: +31 765042300 - www.thetford-europe.com

Loving leisure - around the worldThetford is one of the world's leading suppliers of sanitation system and kitchen appliances for recreationalvehicles. With its new glass production and innovative products, the manufacturer wants to conquer newmarket shares.

Culinary delights in amotorhome, caravan ormobilehome are no lon-

ger a problem with Thetford’srange of hobs, ovens, grills,refrigerators and sinks. Thedesign and function of these kit-chen appliances are based onnormal household appliances.Only high quality materials andcomponents were included in order to achieve the Thetford qualitystandard. The Aspire MK2 is the new complete kitchen solution by Thetfordand offers an oven, grill and hob in one unit. The Aspire boasts aseries of improvements in its second-generation version. It was pos-sible to increase efficiency and lower gas consumption by six percent.There is space for both small and large pans on the conventionalhousehold burners. Placing the optional electric hotplate at the sameheight as the rest of the hob makes it simple to move even the hea-viest of pans around. A new, lowered surface, rounded edges andimproved sealing make cleaning easier. The burners are now five mil-

limetres lower, increasing the safety distance to the cupboards abovethem and this also allows the glass cover to be lowered immediatelyafter cooking without it overheating. The oven heats up 30 percentfaster, reaching 200° C (392° F) in just three minutes. The grill hasbeen enlarged by 30 percent so that the grill pan fits into both theoven and the grill. Another innovation is the heat shield that popsout automatically when the grill is opened. This shield prevents theknobs and the front plate from heating up. The upper section of theAspire is available separately so that the hob can be installed as anindependent cooking area without having to forego the drawersbeneath it. The oven can be retrofitted if required. Great advantagefor the manufacturer: the work surface remains the same.Thetford’s 353 Series offers the perfect combination of three burnersand a sink. The main focus during development was on user friendli-ness. Single-handed operation is a new feature in this price class.Heat can be regulated by turning the knobs and slight pressure acti-vates the electrical 12-volt ignition. The split glass cover provides anadditional work surface and makes kitchen cleaning very easy. Thethree different hob sections are suitable for both larger pans andsmall espresso makers. The entire combination is robust and easy toclean. The use of cast iron grates means that pots and pans not onlystand very stably but also that deformation is a thing of the past. Thestructure of the combination is symmetrical so that OEMs can posi-tion the sink on the right or left side. The large stovetop is thenalways on the opposite side. Both the individual configuration of thetap and the adjustment of the glass cover to the requirements of theOEM are possible. In Europe this new combination is exclusive to theHymer Group. Thetford has been manufacturing glass componentsat its own plant in Sheffield since 2014 and can thus react even moreflexibly and quickly to client requirements. Thetford's new innovative concept is an induction hob. It saves ener-gy and is quicker than common hob. The idea behind is, that almost

Words Jörg Nullmeyer

Dirk Valder

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Contacts:Dirk Valder - Product manager RV OEM International - [email protected] van Noesel - Marketing Manager - [email protected]

every campsiteoffers electricalenergy for a smallfee or even forfree. Domestichobs have a highpower consum-ption, therefore Thetford had to developnew solutions. The result is an induction hobthat is quicker than gas but has a maximumpower consumption of only seven amperesin boost mode. A conventional gas hobneeds 15 minutes to heat one liter of waterfrom 18° C (64° F) to 90 °C (194° F), theinduction hob only needs ten minutes. Otheradvantages are more storage space due toless space requirement, faster cooling downafter cooking and and a reduced safetydistance of 200 millimeters to the next bur-ning material. Anyone who wants to eat and drink well

while travelling needsfresh ingredients and cooldrinks. This makesThetford refrigerators theright choice. ‘Keep it coolat hot temperatures’ isThetford’s motto. Thestandard European tempe-rature class SN (32° C/58°F) for an absorption refri-gerator is no longer suffi-cient in some climatezones. For the first timeThetford is now offeringabsorption refrigeratorsthat are certified forEurope, North America

and Australia. New cooling units achievetemperature class T (40° C / 72° F). ModelN3185 the Australian market has additionalfans to increase its cooling capacity.Thetford also continues its worldwide supplyof compressor refrigerators.

Company ProfileT hetford is a leading global supplier of sanitation

systems for the mobile leisure markets around theworld. Thetford innovations also include high quality coo-king appliances, gas absorption and compressor refrigera-tors, external RV service doors and a wide range of sanitaryand maintenance products. Their products are available

worldwide through local dealers. Thetford is globally head-quartered in Ann Arbor, USA. Their European headquartersare located in Etten-Leur, the Netherlands. Furthermore,Thetford has manufacturing facilities in the United States,the Netherlands, Great Britain, Italy and China. In totalabout 1000 employees make up the Thetford group.

Thetford glass design and production

As a dedicated and well-known key supplier tothe global RV industry, Thetford always strivesfor new innovations that emphasise its leading

position, to continue serving the market in the bestway possible and to meet the latest trends anddemands. Thetford has recently expanded its produc-tion facility in England to include glass manufacturing.This new facility allows Thetford and their OEM par-tners to design and develop their own personalizedvariations of sturdy glass appliances and units. In closecooperation with the OEMs, Thetford is now able tojointly develop premium glass based cooking applian-ces. Limited tooling investments and lead times createflexible opportunities for OEMs that want to distin-guish themselves from the competition. Thetford glassbased quality products can come in various sizes, sha-pes and colours to suit the wishes of the OEMs.Thetford staff have expanded their knowledge baseand brought a new team of glass experts on board.

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Vetroresina Spa - Via Portuense, 10 44020 Masi San Giacomo (FE) - Italy

Ph. +39 0532 327911 - Fax. +39 0532 327110 - Web: www.vetroresina.com

Winning combinationsFrom its successes on the U.S. market to the innovations achieved in partnership with European manufactu-rers, Vetroresina SpA has managed to revolutionize the production of recreational vehicles and is now pre-paring for the challenges of the coming years.

After sampling the reactions and opinions of the visitors to theCaravan Salon in Düsseldorf, and especially those of the experts,Vetroresina SpA is preparing to face 2015 with renewed vigour,

capitalizing on what the market has decreed during the last season. Wehave tried to understand how the productive sector of recreational vehi-cles is evolving by taking stock of the situation with SimoneColombarini, CEO of Vetroresina SpA, surely one of the companies that

at the international level has a direct relationship with most of themanufacturers of “live-in” motorhomes and trailers.

«Our new proposals have met with the approval of manymanufacturers and they are now beginning to adoptthem on their vehicles – declares SimoneColombarini, CEO of Vetroresina SpA – fibreglass, the-refore, is no longer only for the external cladding of

the walls and roof, which are the traditionaluses and where our company now has a

position of leadership in bothEurope and North America. Nowour newly developed laminates,

both the standard and special ver-sions, are being used in more intere-

sting ways, such as the covering offloors and interior walls, usingtechnologies for combining fibre-

glass with other materials duringprocessing.»

Innovation in the U.S. marketOne unique application that hasdemonstrated its ability to surpass tra-

ditional construction processes wasintroduced in the United States back around

2000: it is the product named Vetrolite, desi-gned and patented by Vetroresina SpA – extre-mely thick sheets of fibreglass that combineresistance and lightness thanks to the use ofhollow microspheres of plastic material. On

traditional American motorhomes, the body was

built out of a sandwich which, in addition to the insulating material andthe plywood on the interior of the vehicle, used a thin sheet of fibre-glass (about 1.3 mm thick) on the outer side paired with a sheet of ply-wood about 2.5 mm thick to increase rigidity. American manufacturers,however, were looking for a way to remove the outer layer of wood,which was prone to problems caused by the absorption of moisture.Vetroresina SpA proposed an innovative and revolutionary solution: theVetrolite laminate was a sheet of moisture-resistant fibreglass, whosethickness of 3.8 mm was identical to the previous combination (whichincluded 1.3 mm of fibreglass and 2.5 mm of plywood). The thicknessof the fibreglass sheet, necessary to ensure a certain degree of rigidity,was however quite heavy. This is why we studied the system of themicrospheres, which made it possible to lighten the sheet without com-promising the solidity of the whole. The product had a resounding suc-cess in the U.S. market, such so that Vetroresina SpA had to interveneand build a plant of its own directly in the state of South Carolina,where it now employs 25 people working in a covered area of 10,000square metres. The American production site of Vetroresina SpA is fullydedicated to the recreational vehicle market, apart from a marginalquota devoted to truck refrigerators, and it is expanding its productioncapacity. In the near future volume should increase from the current 1.3million m² of laminates per year to as much as 2 million m² per year.

New applications in EuropeAmerican manufacturers adopt more traditional systems for their floors,which are often a simple sheet of thick wood, 15 or even 20 mm thick,since weight is not such a problem there. The situation is very differentin Europe, where weight problems do exist, and where, therefore, theinnovative proposal of Vetroresina SpA is becoming more and morepopular. And if you combine the water resistance and the strength of

Masi San Giacomo (Ferrara), Italy: production site.


Donaldson Industrial Park (Greenville), U.S.A: production site.

Simone Colombarini

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Contact:Simone Colombarini - [email protected]

fibreglass to the advantage of its light weight,it is easy to see that there is a bright future forthese applications. «In Europe we started toprovide sheets of fibreglass for use in motor-home floors about three years ago – says themanaging director of Vetroresina SpA, SimoneColombarini – particularly at the urging ofHymer. The German company wanted to pro-duce a floor without wood and so we desi-gned the product specifically. Today there aremany manufacturers that use the fibreglass inplace of wood in the lower part of their floors,the part in closest contact with the road andso with splashes of water and debris raised bythe wheels. For some time now we have sup-plied sheets to Pilote, Rapido, Frankia and theTrigano group. There are definitely far lessmanufacturers, however, that use the fibre-glass also for the upper part of the floor, theone in contact with the passenger compar-tment: after Hymer, we have begun supplyingTrigano and Frankia, too. The product is calledVetrostyle PVC and features the joining offibreglass sheets to PVC during the processingphases of the laminate. In this way, the costsof labour and materials for bonding the PVCare avoided because our product is alreadyfinished. Frankia also uses our sheets, shapedto specifications and with chequer plate surfa-ces, to clad the bottom of the garage, whichmust be water- and wear-resistant.»Some companies are also employingVetroresina SpA laminates to finish the inter-nal walls in place of classic plywood, so as tohave a fibreglass-insulation-fibreglass san-dwich. The product is called Vetrostyle and is

sold together with decorative paper. Thepaper is applied with a special process thatfirst saturates it with liquid resin to seal andwaterproof the surface. Vetrostyle is sold in60-metre rolls and is then cut to the correctsize. From the mechanical point of view, themain feature of this application is that thereare no joints or seams, which increases thestrength and resistance of the panel.

Experiments aimed at improvementEven if the above applications can be conside-red novel, in a sector like that of recreationalvehicles, normally slow to implement changes,Vetroresina SpA continues to experiment withinnovative solutions both to improve the pro-duct and to propose new uses. For example, anumber of studies aimed at creating a floorheating system are being carried out.«We noticed that some manufacturers havestarted to offer heated floors, made with hea-ting elements placed between the plywoodand the PVC – continues Simone Colombarini– and in this case our Vetrostyle PVC cannotbe used. That’s why we have developed alaminate that uses carbon fibres as a partialsubstitute for glass fibres, but we are alsotrying to achieve the same result with moretraditional conductive materials.»Vetroresina SpA is also developing productionprocesses that will improve the quality of thefinished product especially from the aestheticpoint of view. In the near future, laminateswith a higher quality aesthetic finish comparedto current products will be introduced, butstudies are also under way to optimize theratio between strength and weight of thelaminates, so as to create lighter sheets.Last but not least, product recycling is also oneof the goals that the company has set foritself. «For some time we have been thinkinghow best to use the leftover fibreglass or evenre-utilise entire walls of campers that have rea-ched the end of their useful life – explains fur-ther Simone Colombarini – and with this in

mind we have recently started working with acouple of companies, and the results are quiteinteresting. For example, adding the milledfibreglass left over from processing to polypro-pylene, in an amount equal to 40% of thewhole, a material is obtained that is suitablefor making various objects. We have alsomanaged to recycle the entire sandwich wallof a camper, including fibreglass, polystyreneand other materials. We obtained a com-pound that can be used for many purposes: asa substrate for shower trays or also as thestructural layer of a table that is then finishedwith other layers. Our goal is to recycle bothour scraps and leftover as well as elements ofvehicles at the end of their useful life, and inthis sense we can also offer this service to ourcustomers.»

Company ProfileEstablished in 1968, Vetroresina

SpA manufactures polyester resinlaminates reinforced with fibreglass.The huge productive capacity of thecompany is the result of careful rese-arch in the field of composite mate-rials associated with the study andthe continuous improvement ofmanufacturing techniques. To main-tain and increase production levels,Vetroresina SpA implemented amajor investment strategy and, withthe help of advanced technologiesand close partnerships with universi-ties and industry experts, it was ableto adapt to the changes and newrequirements of the market.Thesophisticated technological level pai-red with a particular attention toaesthetics and materials have led to adiversification of products and exten-ded their range and areas of applica-tion. Vetroresina SpA has a produc-tion capacity of 129 units per day andcovers an area of 46,000 m². In June2000 Vetroresina SpA opened a plantin Brazil, in the state of São Paulo, inorder to meet the needs of the SouthAmerican market, and since May2008, the company has a productionfacility in the United States, thanks towhich it manages the NorthAmerican market.

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News MARKET & PRODUCTS

Lippert Components, Inc. (LCI®) announces it has reached an agreementwith European RV supplier Project 2000 s.r.l., providing LCI the rights to

distribute and sell the products of Project 2000 to the North American mar-ket. Project 2000’s products include versatile over-cab bed lift systems, powerand manual steps and a variety of power and motion products for RVs.“We are committed to providing premium products to our customers and areexcited to work with a high caliber family-owned company in Project 2000,”said LCI Chief Executive Officer Jason Lippert. “Project 2000’s reputation fordeveloping unique solutions for the needs of RVers aligns perfectly with ourmission to enhance the mobile lifestyle.”Project 2000 Managing Director Davide Nardini is pleased with the arrange-ment and anticipates it will bring his company growth. “We are excited forthe opportunity to work with LCI and grow within a market which is fairlynew for Project 2000. We are convinced that combining our innovation andquality with the strong market presence and commercial capability of LCI willproduce strong results and lead to greater overall customer satisfaction.”LCI Director of International Business Relations Larry Revelino was impressedwhen he visited Project 2000 last year. “Project 2000 has a creative researchand development team and state-of-the-art manufacturing capabilities. Weare really excited to be able to bring Project 2000 products to our customershere in the US.Several OEMs arealready in thedesign and pro-totyping phasewith the over-cabbed lift systemand some arealready in pro-duction.”

Lippert Components®will distributes Project 2000

I n March 2011 we printed the first issue of Aboutcamp BtoB. It was only a 12 pages newsletter but it was desti-nated to grow much further. The magazine you are reading is the 8th number and it is now distributed all over

the world to more than 450 caravan and motorhome manufacturers. We are quaterly at the moment, but the suc-cess of the magazine could bring us to decide for 4 editon per year. We would like to thank all our readers, whorecognized the added value of Aboutcamp BtoB of being updated on the new technologies, products and inno-vation in this industry around the world. But we would like to thank also all the companies that joned us in these4 years. They are our main asset. Our main commitment is to interpret and enhance their communication withindynamic framework. And this can be reached only through a relationship of mutual trust with them.

Four years ago we printed the first issue

Dome t i cG r o u p

and AtwoodM o b i l eP r o d u c t shave signedon Sept. 9, 2014 an agreement where DometicGroup purchase Atwood Mobile Products LLC.The acquisition has received clearance fromantitrust authorities in the U.S. on FridayOctober 17, 2014. Dometic Group, a globalleader of leisure products for the recreationalvehicle (RV), marine, truck and automotive-based industries, therefore, purchased theElkhart, Ind.-based Atwood Mobile Products,LLC, a global provider in designing, enginee-ring and manufacturing appliances and har-dware for the RV, On-/Off-Highway and Marineindustries for over 50 years. This acquisitionwill complement and further diversifyDometic’s existing product offerings and stren-gthen the company’s global footprint.Atwood’s primary markets are North Americaand Australia. The company has 775 employe-es and annual sales of approximately $200 mil-lion. Dometic Group’s global revenue, on a rol-ling 12 months, after the acquisition willamount to approximately $1,400 million andthe number of employees will increase to7,200.

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Dometic Grouppurchased Atwood

Thank you to...

Project 2000 team

Documents

Aboutcamp BtoB n.8