New Corporate Headquarters and Production Plant
In late 2023, our new corporate headquarters and production plant were established in Les Franqueses del Vallès, strategically located 40 minutes from the Port of Barcelona, 45 minutes from Barcelona El Prat and Girona airports, and less than 2 hours by road from the French border. This prime location enables us to deliver any standardized court model within 24 hours.
With over 18 years of experience, we expanded our facilities from 5,000 sq. m to 10,500 sq. m to enhance our production capacity.
Complete in-house production
At AFP Courts, we manage every phase of padel court production in-house to ensure top quality and consistency. The main headquarters now covers 7,000 sq. m and is equipped with state-of-the-art technology. The additional 3,500 sq. m facility in Lliçà de Vall (Barcelona) has been fully upgraded and equipped for the manufacturing of metal structures, specifically for mechanical design, manual and robotic welding, and assembly. At AFP Courts, our production line is meticulously designed to ensure the highest quality and efficiency in manufacturing padel courts. Each step in the process is crucial, from welding to final delivery, ensuring that our courts meet the highest standards of performance and durability.
Product design
Our design process begins with creating detailed renders of the padel courts, ensuring every aspect meets our high standards and client expectations. Once the initial designs are approved, we develop comprehensive technical plans with precise measurements and specifications to guide the construction process. We carefully select high-grade materials that offer durability and performance, improving the longevity and functionality of our padel courts.
Welding
The welding process is fundamental in manufacturing padel courts. This step involves a combination of manual labor and automated welding systems to join metal structures, ensuring strength and durability. Skilled welders work alongside advanced machines, enhancing efficiency and consistency. This synergy guarantees the quality of the courts, optimizing performance and safety for players.
Double-track robotized welding cell
To ensure precision, efficiency, safety, and speed, we have invested in an automated system featuring double-track robotized welding cells with four servo-controlled tables. This system boasts a production capacity of 1,200 courts per year per work shift. We have successfully produced up to 870 padel courts in a single year, showcasing our capability and efficiency.
Painting tunnel
Once the welding process is complete, the metal structures move to the painting tunnel. The automated electrostatic painting plant includes a 181.5-meter-long aerial transponder, a chemical pre-treatment cabin, two cutting-edge paint application booths, and two polymerization ovens. This setup provides superior anticorrosive protection to all metal elements of the court, ensuring higher quality and durability for all delivered metal structures.
Drying tunnel
After painting, the metal structures are placed in climate-controlled drying tunnels. Here, temperature and air circulation are carefully regulated to accelerate solvent evaporation and paint curing. This ensures even heat distribution and prevents imperfections, resulting in optimal finishes. Once dried, the structures are ready for stocking in our storage system.
Stocking & FIFO system
To ensure efficient inventory management and quick access to materials, we utilize a CANTILEVER FIFO racking system for the storage of long loads, managing stock according to the first-in, first-out principle.
Loading docks
With the structures properly stored, we prepare for the loading process. Our facility includes four interior, independent, and simultaneous loading docks equipped with guiding systems, protection buffers, and mobile access ramps. These features facilitate efficient and safe loading operations. Once loaded, the courts are ready for transport and delivery.
Transport & delivery
AFP Courts stands out in logistics and export capabilities. Thanks to our strategic location and production capacity, we can supply any standardized court model within 24 hours. Our plant in Les Franqueses del Vallès is strategically located to reduce delivery times to any corner of the world.
