LABORATORY AND QUALITY
An area of 300 sqm of our factory is dedicated to the test laboratory, a truly unique place. Here we test the quality and safety of our products by carrying out more stringent tests that those specified by the standards.
In addition, every year over 250,000 quality checks on finished products and raw materials are carried out in our factory: an additional assurance for our customers. In fact, 100% of our products that leave the production line are subjected to automated testing before reaching the sales points.
STRIVING FOR TOTAL QUALITY,
Zeca’s technical excellence requires an on-going commitment to improve performance and ensure the safety of all products. Our team of highly specialised professional engineers and technicians has set up a group of specific tests to verify the life, strength,ì and quality of each cable reel, hose reel, lamp and balancer.
Zeca’s laboratory has technologies and machineries specifically designed and manufactured to:
simulate extreme uses
test the effectiveness and efficiency of products under operating stresses
test and select the best components
check the products’ level of quality
test innovative materials and projects
OUR PRODUCT TESTS
All our plastic components that come into direct contact with electric current are tested to make sure that an accidental fire can self extinguish, as required by standard EN 60695-11-5.
The Glow Wire Test simulates the effects of overheating a plastic material in the event of an overloaded connector or of an overheated component.
The purpose of this test is to assess the behaviour of the material in direct contact with electric current, the absence of a fire hazard and its resistance to heat.
Our products are long lasting even in extreme weather conditions. We test our products well over the stated temperature range, from -40° to +80° and from 5% to 90% for humidity.
To check this performance, we use our new generation environmental chamber, which is able to reproduce the most extreme temperatures and humidity conditions.
Here we can test:
1. ageing, with continuous cycles in a -40° to +80° range
2. the life of the batteries/circuits at their maximum temperatures
3. stiffening at low temperatures of different types of cables and hoses
4. Impact resistance at low temperatures of enclosures
5. resistance to humidity
The hose and the fittings can be subjected to sudden changes of pressure.
With Zeca proprietary machinery, we create sudden changes of pressure inside the hose to ensure the resistance and long life of the fittings in the most demanding applications.
During use, the hose is subjected to traction.
By using special machinery, we test the hose traction up to 200kg to ensure its resistance to breaking.
In some operating conditions, the hose may be subjected to sudden tears.
We are able to simulate tears with impulse loads up to 2000N in our laboratory in order to ensure the resistance to stresses of our products.
We guarantee the resistance to wear over time of the on/off switch fitted to our lamps.
To carry out this test, we use our own machinery that presses the on/off button of the lamps. We subject the button to a staggering 100,000 on/off cycles, thus ensuring maximum reliability and long life.
Zeca’s new generation lamps contain LEDs selected to ensure a continuously intense light over the years.
We make sure that the LEDs of our lamps comply with strict quality parameters by selecting quality components, which are tested in-house.
Our rechargeable lamps undergo a test that consists in continuous cycles of switching on, use and recharge, detecting their operating parameters (battery voltage, temperature, charging and operating time).
This test ensures the optimal performance of the product over time.
This tool allows us to measure the specifications of LEDs (luminous flux, colour temperature, colour rendering index).
Whilst in use, lamps can accidentally fall.
To ensure impact resistance of our lamps, we subject them to up to 1000 falls from a height of 1.5m, using a basket manufactured in compliance with standard IEC 600 68-2-31.
Once the test is completed, we check that all the product components are working.
The components of our balancers are tested in order to ensure they keep their standard efficiency over time.
Our balancers undergo full winding and unwinding rope cycles. At the end of the test, we verify that the force exerted by the spring still meets the requirements stated in the nameplate.
All the components of our reels are tested to ensure they can withstand the operating stresses they are subjected to over time.
We simulate the intensive and continuous use of cable and hose reels by means of automatic unwinding/rewinding cycles. This allows us to test the life of the product.
This test checks the IP rating of a product, i.e. its level of protection from the ingress of water:
- IPX2: Protected from drops of water fallen at a 15° angle
- IPX3: Protected from the rain
- IPX4: Protected from water sprays
- IPX5: Protected from water jets (10 litres per minute)
The light intensity of rechargeable lamps can be greatly reduced whilst in use.
To make sure that our quality parameters are complied with, the light intensity of our lamps is measured in lux.
By carrying out this test, we subject our hoses and fittings to a high pressure, up to three times higher than the values stated in the nameplate to check their strength and quality.
The magnets are essential in order to keep the lamps in position and consistently direct the light beam where it is required. During this test, a dynamometer measures the minimum force required to remove a magnet from a metal surface.