BlueCool V-PRO Series: a global success story for the Webasto marine team

Advancements in modern maritime technology have been significant recently, touching on navigation, safety, and comfort. But what exactly makes a boat or yacht comfortable? Air conditioning is often an overlooked factor. Not only does it regulate temperature, but it also controls humidity, which is particularly important in salty sea air. Proper climate control on board contributes to general well-being and markedly improves the overall sea-going experience.

“In the past, the focus at Webasto was mainly on independent, stand-alone systems,” states Uwe Nolte, Product Manager at Webasto. “However, with the new V-PRO Chiller Series, we’re shifting gears. Our goal is to create systems that can communicate intelligently with one another,” says Uwe. “This is achieved through a blend of network technology and tailored software solutions. The unique feature is that the individual components can self-organize; they recognize each other and can dynamically adjust performance to meet specific needs, significantly enhancing the overall system efficiency.”

Another objective was to facilitate system control from various locations on the ship. Chiller systems are usually located in less accessible engine rooms, so the plan was to increase the cooling capacity to a total output of one million BTUs.

Agile development during the COVID-19 pandemic

Before embarking on these ambitious aims, the team carried out a thorough evaluation of the project’s global market potential. Starting in 2019, they conducted extensive interviews with market participants. “U.S. market requirements significantly differ from those in European or Asian markets. Since we distribute our marine products globally, they must conform to a wide variety of local requirements,” notes Uwe.

The COVID-19 pandemic led to mostly remote development, making agile project management essential. “Our bi-weekly sprints, daily stand-ups, and fortnightly review meetings became core components of our workflow. Wherever feasible, we also arranged in-person meetings to sustain team morale and motivation,” Uwe elaborates.

A modular system for a global marine market

The BlueCool V-PRO Series from Webasto exemplifies global teamwork and distribution. “Our marine unit at Webasto Customized Solutions is a strong global team. Supported by colleagues from the UK, the Netherlands, Turkey, and France, we refined the conditions, roles, and specifications for the main units in Germany,” says Uwe. The team took advantage of its international setup during the testing phase, conducting some tests in Hengersberg, others in Neubrandenburg, and still more in Tuzla, Turkey. With the adoption of the latest inverter technology in mind, CE certifications and EMC tests were undertaken in partnership with external labs in Germany.

The development project also benefited from other sectors within the company. “In the thermal management area of Webasto, we had access to various resources, including the development department for modular platform software,” says Uwe. The entirely redesigned software represents a significant advancement in both user-friendliness and system interoperability.

Global sourcing for high-efficiency products

Alongside an internationally coordinated development effort, the project places high emphasis on global material sourcing. “The international procurement of materials and components is vital for us to ensure high quality and performance,” explains Uwe. Materials integrated into the V-PRO Series come from around the globe: from the manufacturing of compact refrigeration circuits and corrosion-resistant stainless-steel parts in Turkey to electronic components from Bavaria that form the technological core of the systems.

But that’s not all. In China, specialized compressor and inverter components are manufactured, while Italy and the Netherlands contribute other key parts and accessories. This global approach extends to the external electronics development, completed in close collaboration with a team from Saint-Viaud in France and finalized by another team in Kampen. This wide array of international suppliers clearly shows that the V-PRO Series is a true product of global expertise.

From prototype to production

Prototypes serve as a critical stage in a lengthy product development process. Their performance is tested under real-world conditions at the climate test facility in Gilching. Multiple test rounds allowed the chiller unit to demonstrate its capabilities, enabling the team to validate their previously CAD-designed concepts and technical innovations in real-world operation.

To gauge customer acceptance, the marine team created special samples to showcase at important trade fairs. One such prototype was presented at the Genoa Boat Show in Italy, a hub for the super yacht industry. Another presentation occurred last year at the Marine Equipment Trade Show (METS) in Amsterdam, where the V-PRO was honored with a DAME Award nomination. This international jury award stands for innovative design in functionality, user-friendliness, and sustainability.

Leveraging expertise for future developments

With the successful unveiling and subsequent positive market responses, the V-PRO Series is now production-ready. “It’s not just the high cooling capacity that sets our new V-PRO Series apart, but its entire modular concept and system functionality,” emphasizes Uwe.

The development of the V-PRO Series, from initial concept to market readiness, strikingly illustrates the depth and complexity that can exist even in a project that may outwardly appear as just an “unassuming white casing” in an engine room. “We can now apply this knowledge to our smaller VX Series, allowing us to offer a comprehensive product portfolio,” Uwe adds. The V-PRO Series chillers serve as an excellent example of how international collaboration, high-caliber engineering, and clear project management can coalesce into a globally successful product.

“This project has been a great journey for the entire team at Webasto, and we’re excited about the future possibilities that this new series brings,” Uwe concludes. The BlueCool V-PRO Series, a pivotal offering from Webasto, has already proven its worth in the market, signifying another milestone for Webasto in delivering innovative solutions for maritime comfort.