Production Reasons

Whirlcare® Production

Sustainability
Environment
Energy
CO₂ Savings

modern
FULLY AUTOMATED

All-automatic

Whirlcare’s hot tubs and swim spas are made in the Swabian town of Deißlingen-Lauffen near Rottweil. The production in the industry standard 4.0 with fully automated, robotic manufacturing processes and networked intralogistics guarantees consistent high quality in consideration of ecological and economic aspects.

The spa bath and swim spa tubs are made
by huge, specially designed machines in a
thermoforming process and directly
afterwards automatically reinforced.
Swim spas with a length of up to twelve
meters – and thus the largest
the world – can be produced here.

Modern

High-tech robots spray on the recyclable PU material. At a 31 metre long CNC machining centre, the tubs are further processed before the final assembly takes place. A fully automated guided vehicle system, which accesses modern storage towers, takes the required components to the respective workstations. Many new spa bath models in various editions, along with the revolutionary Smart Spa and our exclusive swim spas will ensure you’re guaranteed to find the right Whirlcare for your feel-good oasis.

Near you

Anyone who produces hot tubs and swim spas in Germany must clearly distinguish themselves against the competition from low-wage countries. This is where Whirlcare scores with innovations, a modern, anatomically correct design, responsibility for the environment and the use of pollutant-free, durable and energy-efficient materials. As a customer or dealer you benefit from a reliable partner without long transport routes and the advantages of a German manufacturer with Europe’s largest and most modern hot tub and swim spa production facility.

INTEGRAL
NETWORK

Automated guided vehicle systems bridge long distances
via WLAN and lane assistance

Our automated guided vehicle systems ensure fast material transport and reduce walking distances. Their use is therefore standard at Whirlcare® Industries.
Our systems communicate via WLAN on the one hand and via lane assistants on the other hand. These automated processes ensure that the required components are available at the right time at each workstation and that no paths are blocked.

Also linked to the region 
For us, transparency and the exchange of information with the people in Deißlingen-Lauffen are also part of networking and responsibility.

ENVIRONMENTAL
FACTOR

Lie relaxed in warm water and enjoy a soothing massage while the snow􀃸akes are dancing around you; dreamily look at the sunset or smell the scent of approaching spring and feel the stress of everyday life disappear. In an outdoor pool, we enjoy intensive contact with environment and nature. And that’s why
their preservation is very important to us.

In our state-of-the-art production facility at the company’s headquarters in Deißlingen-Lauffen, we generate significant parts of the electricity we require ourselves: a powerful photovoltaic system ensures that an energy surplus of 441,510 kilowatt hours can be used in production. Adding CO2 savings through advanced LED lighting technology adds up to a total of 424,000 kg of CO2, which are spared the environment. A second photovoltaic system is being planned.

We are not only responsible for what we do,
but also for what we do not do.
(Molière)

RESPONSIBILITY

Out of responsibility for our environment, we place emphasis on resource-efficient, sustainable production, and durable materials that are free of pollutants and recyclable. Anyone who buys a Whirlcare spa bath today will not have to dispose of it as hazardous waste in 20 years’ time. To achieve this, the reinforcement of our whirlpool tubs is not carried out, as is so often the case, with environmentally harmful glass fibre, but using a multi-component reaction system based on
polyurethane. The eco-friendly and recyclable PU material contains no plasticisers or solvents. Most manufacturers use impregnated wood or WPC (wood-polymer materials) for the tub frame. The frame of a Whirlcare pool, however, consists of highly stable, CDC-coated steel. This increases the product’s lifespan and means it is still recyclable after umpteen years.

The Protective Panels of our hot tubs are also fully recyclable. They are made of a high-class and durable material that is free of formaldehyde or other toxic substances. This material is of much higher quality than conventional wood or plastic coverings, which require maintenance and quickly become unsightly
due to weathering. The outer lining is characterised by durability and non-fade properties, and even after ten years time it will look almost the same as it did on the day of delivery.

ENERGY
FACTOR

ISO GREEN not only reduces the energy costs,
but also the maintenance costs

When you get into your hot tub, you want to relax and not worry about electricity costs. The fact is that heating water takes a great deal of energy. Therefore, the type of insulation and the so-called U-value (thermal conductivity) are of particular importance. PU foam or silver-foil-coated polystyrene foam is often used to insulate the whirlpool tubs – it is inexpensive to produce, but it is much more expensive from an ecological and economic point of view. By contrast, Whirlcare uses the chemically and biologically neutral Iso Green high-performance insulation – free from CFCs, HCFCs and HFCs and, of course, fully recyclable.

Iso Green stands for a modern, environmentally-conscious lifestyle. The graphite particles contained in it reflect the heat emitted by the pumps and the whirl tub, which is why no silver-reflecting foil is required.

Iso Green achieves a low-emission energy standard with a U-value of 0.32. To achieve the same high insulation efficiency, you would need brickwork which is 55 cm thick!

Whirlpool tubs with poorer insulation are usually a bit cheaper to buy. However, you will then often have to pay the price of higher energy costs in the long term. Assuming an average spa life of 20 years, the difference in whether you pay 40 or 80 Euros per month for the electricity adds up to the impressive sum of 9,600 Euros!

Whirlcare is the only manufacturer in the world with its own climatic chamber, where the hot tubs and swim spas are reviewed and optimised in relation to energy usage and conservation. The climate values from the most varied regions provide us with reliable data on how much electricity your hot tub really needs. Whether your spa bath is in Stuttgart, Moscow or Barcelona: from now on, energy costs are no longer a secret matter.

TRANSPARENCY

How is the weather with you?
The Whirlcare® climatic chamber - Only facts count!
 

Since the essential components of a hot tub or swim spa are hidden behind the exterior panelling, the look alone does not say anything about the quality. For the end customer, it is therefore usually very difficult to recognise the difference between a low-quality and a high-quality spa bath. This will now change: with its
own professional climatic chamber, Whirlcare Industries is revolutionising the global spa market and setting new standards.
15 metres long, four metres wide and three metres high: These are the impressive dimensions of the climatic chamber that Whirlcare uses to test and develop its new, energy-efficient hot tubs and swim spas. It is the prerequisite for testing and verifying pools with a length of up to twelve meters in long-term operation under simulated, realistic and application-specific conditions. This simulates, for example, temperature and humidity profiles, UV radiation and vibrations, noise and sound, but above all the actual energy consumption depending on climatic conditions.

Whether a hot tub is set up and operated in Spain or in Stuttgart makes a big difference. For this reason, the different climatic conditions of individual countries or regions – such as temperature or humidity – can be closely modelled in the factory’s climatic chamber. Thus, with an assumed average service life and water
temperature under the respective climatic conditions, the actual energy consumption can be determined and verified. At the same time, long-term tests and comparisons can be made for the materials, components and insulations used, as well as quality and longevity being decisively improved.

This contributes to the allocation of so-called energy labels or energy classes from D to A +++ and the average energy consumption in the year, as in the case of refrigerators, even for hot tubs and swim spas. A sound measurement also provides information about the noise level in decibels during the circulation of
the water or during operation. This is especially important if a whirlpool tub is to be installed right next to your neighbours or a bedroom.
The measuring instruments used collect and record data on the water and outdoor temperature, air humidity, sound level and energy consumption. All measurement data, including video surveillance, is reliably and completely archived, and faults and limit value breaches are reported via switch output, SMS
or email. The professional software clearly displays all information in visualisation charts and diagrams and provides quick access to current and previous data.

The introduction of an energy label, which is of particular concern to us, will improve the quality of the products and bring more transparency to the market. At Whirlcare, we believe that an energy efficiency label for hot tubs and swim spas will become the norm in the coming years. This will allow the end user to
quickly identify bad heat and sound insulation, inferior coverage, or loud circulation pumps based on the information, making it easier to reach a decision.