Lett-Tak
Scalable automation for large roof elements
Company: Prefabricated roof manufacturer in the Nordics delivering custom roof systems for commercial and public buildings for over 40 years
Challenge: Automating production of a new low-carbon, load-bearing roof element with strict requirements for structural strength, precision gluing and accurate fastening.
Solution: Delivery of three automated production stations — a custom-built framing station with a TB24 multifunction bridge, a butterfly table with a working station, and an additional working station — forming the first phase of a new production line for roof elements measuring 16 x 2,5 meters.
Result: Reliable production process, validated structural safety, and a platform for continued growth in sustainable roof solutions.
Triweco stood out because they took the time to understand how we actually work. We wanted to set a new industry standard for sustainable roof elements, which required a production line with zero compromises on quality or the environment. Instead of pushing standard solutions, they asked what we needed and what we wanted to achieve. That created a strong foundation for real collaboration.
The Company
Lett-Tak is a leading Nordic manufacturer of prefabricated roof elements and roofing systems, with more than 40 years of experience delivering custom roof solutions for commercial, industrial and public buildings. They design, manufacture and install energy-efficient roof structures that enable long spans, fast installation and reduced construction time. With a strong focus on sustainability, low climate impact and predictable project delivery, Lett-Tak helps contractors and developers meet modern building requirements while improving efficiency on site.
The Challenge
Lett-Tak needed a partner who could help automate the production line for their new low-carbon roof element, Lett-Tak Wood. Designed to significantly reduce CO₂ emissions compared to traditional roof systems, the product represents the next generation of prefabricated, load-bearing roof elements and demanded a highly controlled and repeatable manufacturing process. For Lett-Tak, it was crucial that the new production process itself reflected the sustainable profile of Lett-Tak Wood. Minimizing material waste, optimizing resource use, and ensuring an energy-efficient manufacturing line were key priorities from day one.
The roof elements are large in all dimensions, measuring 16 x 2,5 meters — substantially taller than typical wall elements — creating complex requirements for material handling, positioning and automation. Precision is critical: the correct amount of glue must be applied in the exact locations, and nails must be positioned accurately to ensure structural strength. Because the product is a load-bearing roof structure, the manufacturing process must be extremely reliable and repeatable to achieve the required strength and structural performance in every element.
The Solution
After looking at other suppliers, Lett-Tak selected Triweco based on a clear alignment in both mindset and approach. Rather than offering a standard solution, Triweco focused on understanding how the system would be used in practice and delivering a solution to meet Lett-Tak's needs. The new product also shared similarities with building elements Triweco had previously delivered machinery for, making us uniquely suited for the challenge.
As a first phase, Triweco focused on optimizing production flow using the right combination of tools and automation. Together, Lett-Tak and Triweco developed a customized production line specifically adapted to the Lett-Tak Wood system – designed not as an off-the-shelf product, but as a solution built around their unique processes and production needs.
Triweco delivered three key stations: a framing station with a TB24 multifunction bridge, a butterfly table with a working station, and an additional working station. This solution was designed to handle the large roof elements efficiently while ensuring precise adhesive application and accurate fastening — both essential for structural performance and quality control.
The line begins with a custom-built framing station and multifunction bridge. The framing station controls and aligns the beams in the structure, with easy adjustment of the CC distance between the beams. The multifunction bridge is capable of both adhesive application and nailing, with straightforward programming by the operator of measurements to accommodate different elements. The framing station is followed by a series of stations that rotate and transport the roof elements. The solution includes several innovative features, including automatic cleaning of surfaces to be glued, glue application with controlled flow rates, and precise flipping of the element, with automatic adjustment of flippers based on the element’s thickness.
The next phase of the project will focus on further automation of the remaining production line, moving toward a fully integrated and efficient manufacturing line.
The Results
The automated production line has delivered reliable performance from the start, creating a stable and repeatable process for manufacturing the new low-carbon roof element, Lett-Tak Wood. The product has undergone a technical assessment by Eurofins and meets EU requirements for structural safety, validating both the product and the production process.
The line has delivered strong results in terms of efficiency, achieving fewer labour hours per square meter than initially anticipated. By significantly reducing production time per square meter, Lett-Tak has increased its factory capacity. This ensures high delivery reliability and enables the company to meet the rapidly growing market demand for sustainable building materials without compromising on lead times.
The new line has also delivered significant improvements in the working environment – by replacing traditional nail guns with press-based fastening, noise levels have been reduced from over 100 dB to approximately 75-80 dB. This creates a quieter and safer workspace, contributing to better conditions for operators and a more attractive production environment. In addition, increased precision on adhesive application has enabled Lett-Tak to reduce glue consumption, while maintaining structural strength. As adhesive is both a cost factor and environmental consideration, this has contributed to improved sustainability as well as operational efficiency.
Triweco’s production line has established a robust foundation for continued automation and long-term growth in prefabricated roof element manufacturing.
It’s exciting to be part of the development of an innovative, environmentally friendly product and to work with a company that is committed to moving the industry forward. Projects like this show how Triweco’s automation and production machinery can enable new, more sustainable building solutions.