Haco A/S, a Danish family-owned enterprise, has significantly bolstered its manufacturing capabilities for the burgeoning offshore wind sector with the installation of its second large machine from Starrag. This strategic enhancement now enables the company to more efficiently and precisely machine colossal rotor housings and brake discs specifically designed for the next generation of 14 to 15-megawatt (MW) offshore wind turbines. This move positions Haco at the forefront of the supply chain for high-capacity wind energy components, addressing the industry's increasing demand for larger, more powerful turbines and solidifying Denmark's role as a key manufacturing hub.
The small town of Rødekro in Southern Denmark is rapidly emerging as a pivotal logistical hub for the offshore wind industry. Its close proximity to the port of Esbjerg, Northern Europe's leading offshore wind hub, alongside the ports of Aabenraa and Sønderborg, facilitates seamless and efficient transport routes for oversized wind energy components. This regional synergy, exemplified by the close collaboration between Haco and SM Industrie A/S, a key supplier of steel wind energy components, underscores a commitment to sustainable and localized logistics within the sector. The new Starrag machine duo is strategically housed within SM Industrie's premises.
The recently commissioned machine duo comprises a large Droop+Rein gantry machine, operational since early 2024, and a complementary Dörries machine. Both units are engineered to machine exceptionally large workpieces, with the Droop+Rein capable of single-clamping operations for massive components. This expanded machining range, coupled with an enhanced main drive and increased workpiece swing diameter, allows Haco to precisely manufacture larger welded rotor housings and other substantial components, including those with diameters around 9 meters, maintaining an exacting accuracy range of ±0.1mm. "We are setting a new benchmark in machining workpieces for gearless wind turbines in the 14 and 15MW power classes," stated Hubert Erz, senior consultant sales/renewables at Starrag.
The wind energy industry's stringent specifications for large components necessitate such high precision. Starrag achieves this through meticulous calculation and dimensioning of main components using advanced design tools, precise mechanical components, and robust machine foundations designed for static and dynamic loads. Haco's commitment to production reliability is also evident in its decision to utilize an existing, proven Siemens control system, prioritizing continuity and employee flexibility. Furthermore, Haco invested significantly in programming and simulation capabilities, enabling pre-simulation of NC programs and measuring routines to substantially increase productive machine running time. The second machine also features a modern magazine concept with automatic tool loading and unloading, facilitating flexible and accurate machining in a single clamping operation.
The installation of these two 870-ton machines required a bespoke, two-storey basement foundation capable of withstanding colossal static and dynamic loads. This collaborative effort between Haco and Starrag also minimized noise emissions, enhancing the work environment. Developed by Starrag's LPMS (Large Parts Machining Systems) business unit, the machine duo adheres to the VDMA Blue Competence label's strict criteria, incorporating energy-optimized components, advanced drive technology, and surplus energy recovery systems. These measures collectively reduce energy consumption and material waste, providing a significant competitive advantage in an industry focused on environmental stewardship.
This substantial investment positions Haco to capitalize on current and future demands for large components in the wind energy sector. The flexible design and comprehensive equipment offer virtually limitless capabilities for machining oversized components, preparing Haco to meet the stringent requirements of the next generation of wind turbines. Managing Director Henning Albrechtsen highlighted their strategy of perfecting complete machining with minimal clamping operations and expanding their product portfolio to include castings like generator housings and adapter components, ensuring Haco is ideally prepared for the future of wind energy.