Fruehauf, recognised for pioneering trailer engineering in the UK, continues to strengthen its reputation for build quality and reliability through strategic investment in advanced welding technologies. At its Grantham headquarters, the company produces more than 500 tipping and bulk trailers each year, managing the complete manufacturing process in‑house — from raw material to finished trailer. A key part of this operation is Fruehauf’s extensive use of Fronius welding systems. The manufacturer currently relies on 31 TPS 400i MIG/MAG power sources, an iWave 300i AC/DC, and, more recently, a FlexTrack 45 Pro rail‑guided welding carriage, all of which play an essential role in delivering consistent, structurally robust welds across steel and aluminium components.
“For the past two years, we’ve relied on Fronius welding systems because their offerings align perfectly with our core values of commitment to quality and reliability,” says Artūras Mitunevičius, Production Director at Fruehauf. “As a valued partner, Fronius consistently provides insightful advice and introduces cutting‑edge products that enhance our operations. The continuous technical advancements, such as those found in the TPS 400i and its exceptional welding capabilities, have significantly improved our performance by increasing the speed and flexibility of our manufacturing processes. These systems enable us to confidently deliver the dependable products our reputation is built upon, ensuring that their strength and reliability remain unmatched–qualities that result in almost zero warranty issues.”
High‑quality welding for demanding trailer applications
Every Fruehauf trailer includes a significant number of welded joints, many located in areas subjected to intense mechanical stress, such as shock, vibration and torsion. Maintaining weld integrity is therefore essential.
“We take great pride in our weld quality. Defective welds can lead to significant issues and so we have very strict standards regarding the quality of our welds. We focus particularly on ensuring flawless welds in the load‑bearing parts such as the load support structure or subframe, where we use high tensile S700MC steel. Additionally, we ensure that all welds are aesthetically pleasing as they are visible on the exterior of the trailers,” Artūras continues.
This emphasis on weld quality is particularly important for Fruehauf’s lightweight aluminium bodies, capable of handling payloads of up to 30 tonnes while reducing trailer weight by as much as 250 kg. Welding aluminium, however, brings challenges such as heat distortion, porosity, and the difficulty of joining thick to thin sections. These challenges are addressed head‑on through the capabilities of the Fronius TPS 400i.
Fronius TPS 400i: precision‑tuned welding for complex aluminium joints
The TPS 400i is central to Fruehauf’s aluminium fabrication processes. Its intelligent control functions—including Penetration Stabiliser and Arc Length Stabiliser—help maintain stable weld geometry and reduce heat‑related distortion. Operators at Fruehauf make extensive use of the Pulse process, particularly valuable when welding 5–6 mm top rails to 2.2 mm aluminium panels. The Pulse process help deliver enough heat to the thick section while safeguarding the thinner material from overheating.
Fruehauf has also equipped the TPS/i systems with Fronius JobMaster Push‑Pull torches featuring a 10‑metre hose pack, improving wire feed reliability and usability during long, continuous welds.
Artūras explains, “Before we introduced the Fronius TPS/i machines, we frequently encountered wirefeed issues and consequently had to change the liner regularly. We have been using the 10m Fronius Push Pull torch, which includes a motorised pull system that synchronises with the wire feeder, ensuring uninterrupted wire feed. Since adopting these we have significantly increased efficiency. We opted for the Job Master model so the welder can select parameters, including pre‑saved jobs, directly on the torch without having to return to the machine. This is very convenient when you are welding body lengths of 9‑12 metres. The user‑interface on the screen is also relatively simple to use.”
The torch’s “EasyJob” feature allows operators to store and switch between five commonly used welding procedures directly on the torch body — an important benefit given the length and complexity of trailer body welds.
Introducing automation: FlexTrack 45 Pro enhances efficiency and consistency
As part of its ongoing improvement strategy, Fruehauf has introduced semi‑automated welding to its production line. The FlexTrack 45 Pro, used in combination with a TPS 400i, welds the longitudinal seams of aluminium sidewall panels mounted in a purpose‑built jig.
This approach has proven significantly more cost‑effective than a fully robotic system while still delivering major productivity gains. The FlexTrack welding carriage ensures smooth, consistent travel speed and reduced operator fatigue, while improving the repeatability of weld quality.
Following months of internal testing and adaptation within Fruehauf’s R&D department, the FlexTrack system has been in daily production use since June 2024.
Artūras notes that the impact has been substantial: the company saves around one hour of welding time per sidewall, resulting in 800–1,000 labour hours saved per year, equal to £20,000–£25,000 in annual cost savings. The investment paid for itself in under two years.
“Today, it is difficult to envision our aluminium body production without the FlexTrack welding equipment. It ensures perfect reproducibility of welding results, especially when used with the TPS/i welding source,” he says. “We have also found the FlexTrack to be very reliable. We have been operating this application for 18 months without experiencing a single breakdown.”
A future built on efficiency, quality and innovation
Fruehauf continues to refine its welding processes to improve comfort for operators and to fine‑tune parameters for the highest possible weld quality. The combination of advanced Fronius welding systems and targeted automation supports Fruehauf’s long‑established engineering strengths while positioning the company for future growth.By integrating precision‑focused technology such as the TPS 400i and FlexTrack 45 Pro, Fruehauf reinforces its commitment to delivering UK‑built trailers with consistently high structural integrity, aesthetic finish, and long‑term reliability — qualities that remain central to its reputation in the bulk trailer market.
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