Charl-Pol, a Canadian fabricator specializing in large, welded assemblies with over 100 years’ experience, was looking to increase capacity, reduce cycle times, and improve operator safety through automation. They partnered with Pemamek to implement a flexible, large-scale robotic welding solution tailored to their production environment.
Founded in 1920, Charl-Pol operates five production sites across Canada, serving high-spec industries including shipbuilding, mining, energy, and aluminum. Its core expertise lies in the fabrication and machining of large, heavy-duty welded components.
“We specialize in large-scale welding and machining. Our customers bring us their most demanding challenges, and we deliver with world-class quality and reliability”, says Gabriel Tremblay, General Manager at Charl-Pol.
As industry requirements evolve, Charl-Pol has made automation a central pillar of its operational strategy, aiming to improve throughput, reduce manual rework, and maintain a competitive edge amid labor shortages and increasing complexity.
In search of the right partner
Before teaming up with Pemamek, Charl-Pol already had a clear vision for automating its welding processes. The company had been planning a large-scale automation project for some time but had not yet found a partner willing to tackle the complexities involved.
“We had a project in mind for years, but we needed a partner ready to engage with us at a detailed level. Flexibility, scale, and responsiveness were key.”
While preparing for a customer meeting in Finland in early 2023, the Charl-Pol team decided it would be worthwhile to visit other potential companies in the area.
“We searched online, found Pemamek, and decided to send an email through your website, not actually expecting a reply. Surprisingly, the next day we got a response from Jukka Rantala saying they’d be happy to have us at the factory. So, we made our way to Finland, visited our client, and then headed to Pemamek,” Gabriel recalls.
That visit turned out to be a turning point and confirmed that Pemamek had what Charl-Pol was looking for: advanced automation experience, a modular engineering approach, and a willingness to collaborate.
“It felt like Christmas for machine shop guys,” Gabriel says. “We walked in, saw the scale of Pemamek’s operation, and knew we had to show our project. When we showed Jukka and Tommi our requirements, they looked at each other and said, ‘I think we can make something work.’ That’s when we knew we were in the right place.”
Cooperation from vision to execution
After the first meeting, the teams from Pemamek and Charl-Pol worked together on the design, tailoring it to Charl-Pol’s limited floor space and specific welding requirements. By May, Charl-Pol ‘s full management team returned to Finland for a second visit for hands-on testing of complex weld joints.
“From first contact in January to placing an order by May, it was fast. But for us, this project had been in the works for years. We just needed the right partner and the right moment,” says Gabriel.
Despite the vision, there were internal concerns, especially around robotics programming and operator training. The team’s experience with automation had been limited to small-scale, one-off projects.
Charl-Pol hired a tech-savvy team member who trained with Pemamek in Finland during the Factory Acceptance Test. Operators were later trained on-site in Canada during installation and Site Acceptance Testing.
“The onboarding process was faster than expected. Within one week, our team was confident operating the system. Today, we have six trained operators, four dedicated full-time, and we’re preparing to add a weekend shift.”
The full process from concept to operational deployment took approximately 15 months, including system engineering, delivery, installation, commissioning, and ramp-up.
“The transition to robotics was far smoother than anticipated. We were told it would be easy to train, and that’s what happened. Now we’re running two shifts, with excellent continuity.”
Automation as a strategic choice
Automation is now a strategic priority at Charl-Pol. As the heavy fabrication sector is changing, they see automation as an essential part of operations. The company is already planning further developments and sees Pemamek as a key technological partner.
“Automation is no longer optional, it’s essential. This project has helped us to compete at a higher level, both in capacity and quality. We would recommend Pemamek without hesitation. The equipment delivered, the process was professional, and the collaboration was first-rate.”
Results & impact of implementing automation
Operational gains:
- 40% cycle time reduction: from 7.5 days to 4.5 days for key components
- Improved floor space utilization
- Enhanced safety and ergonomics: fewer welding fumes and gouging
- Improved weld consistency and quality through robotic precision
Organizational gains:
- Rapid operator upskilling with a user-friendly interface
- High system reliability during extended shift operations
- Scalable foundation for future automation investments
Keys to a succesful welding automation investment
According to Charl-Pol, three factors made the project a success:
- Engineering expertise: “What felt like a large project to us was standard for Pemamek. Their experience gave us confidence.”
- Strong communication and flexibility: “The team was responsive, transparent, and adapted the solution to our constraints.”
- Simplicity: “The software was intuitive. That was critical, since our in-house robotics experience was limited.”
