Sometimes, technical modifications to a project that has already been agreed upon and underway for some time can significantly enhance the quality of an assembly or semi-finished product in terms of functionality, aesthetics, and, not least, cost efficiency. These changes often align with the arrival of cutting-edge, more advanced technologies.

When Metal’s adds new, project-relevant equipment to its machine fleet, our technical department evaluates potential enhancements to the work. Before suggesting an alternative solution to the client—especially if the production process is stable and well-established—this solution is always rigorously tested in-house.

This is one of the many advantages of choosing Metal’s as your sole project partner. We can assess and implement specific improvements mid-process to refine the product and its final outcome in the client’s best interest, all without affecting the agreed timelines.

Technical modifications to an ongoing project: all the benefits for production explained in our case history

At Metal’s, we often suggest technical modifications to a production process that has already been tested and approved. Even when a client is satisfied with the current operations, we continuously seek new challenges. One of our key goals is to recommend targeted strategies to optimize costs, enhance product aesthetics, or improve the entire production cycle (including reducing delivery times where possible).

In this case study, we explain how it’s possible to implement enhancements for any project and how we achieve it.

The case and the proposal in brief: enhanced results through the adoption of new technologies

At Metal’s, we can recommend the most advanced technologies to reduce production costs, accelerate workflows, or achieve better products than the original design.

This case involves two international clients in the Food Processing industry who have trusted Metal’s for years to manufacture rotisserie ovens and fryers. We proposed transitioning their production technology from traditional welding to laser welding to fully leverage its advantages.

Our proposal: an upgrade to the production process

Metal’s boasts a vast machine fleet that allows us to perform specialized processing and finishing for stainless steel, including welding, bending, and brushing. As part of our commitment to business improvement—and to ensure our clients receive the excellence they need—we invest in cutting-edge equipment. These advanced machines refine and enhance our production systems.

For two clients in the Food Processing sector who require specialized welding and high-end aesthetic finishes, we suggested adopting laser technology.

The benefits?

• Versatility, cleanliness, and precision;
• Improved aesthetics of finishes;
• Low heat input (ideal for preventing metal deformation);
• Reduced material waste;
• Faster processing times.

Two scenarios, one outcome: the advantages of new technologies for two food processing clients

Technologies are constantly evolving, enabling us to better meet the needs of every sector and market. When we identify that a new machine added to our production system could be a significant advantage for specific clients, we propose a tailored alternative solution. In doing so, we ensure that all initial objectives are respected and clearly demonstrate the potential final result achievable through the modification.

This is exactly what happened with two of our clients in the Food Processing sector who manufacture professional rotisseries and fryers. Here’s what we proposed and the results achieved.

Case 1: Improved aesthetics with laser technology

For an international client, we manufacture rotisserie ovens intended for large-scale distribution. For several years, we have been producing this product with excellent results, following a production process that includes: traditional welding, passivation, and localized pickling, with predefined costs from the outset. As we increasingly employed laser welding for other projects, we realized this technology could enhance the aesthetic appeal of the product.

Before proposing an alternative solution to the client, we conducted several tests, pushing the product to its limits. This allowed us to confirm that even the thin sections of the product could be easily welded and that the material remained as linear as possible. After confirming a 70% improvement in aesthetics, we suggested this new technique to the client. Once the proposal was approved, we modified production to incorporate the new process.

Case 2: Optimized functionality with laser technology

Laser technology was also proposed to another client for whom we have been manufacturing professional fryers for the restaurant industry for many years. This is a product with highly robust welds, designed to meet high-quality and aesthetic standards. In this case as well, we tested the modifications on the product to evaluate the improvements brought by the new procedure compared to the previous one. Given the advantages of laser welding (better performance, no impact on aesthetics, and significant savings on final costs), the process was revised accordingly.

The importance of testing before making proposals

At Metal’s, before proposing any potential improvements to production processes, we always carry out a series of specific tests. In the examples provided, we focused on the quality of the welds, seeking enhancements in terms of functionality, speed, aesthetics, and costs.

Rotisserie ovens and fryers are highly delicate products that are subjected to prolonged exposure to high temperatures (and frequent washes with cold water). Although stainless steel is a durable material – ideal for the food industry – the constant thermal expansion of the walls can pose a significant challenge for manufacturers of complex assemblies and/or semi-finished products, especially when oils are involved. For this reason, the welds must be watertight, long-lasting, and resistant to the stresses caused by heat.

Before suggesting any modification, we always ensure that there is a real improvement and quantify it. We perform various tests, from mechanical stress to breakage tests, presenting the results to the client to highlight the potential advantages they could gain from the proposed change. If the client approves the adjustment, we proceed with prototyping and implement the actual modification.

“At Metal’s, we always leverage new technologies that can enhance an ongoing project. Laser welding is a prime example, enabling us to deliver projects with superior aesthetics, cost efficiency, and functionality. We conduct thorough tests to substantiate our recommendations, which we then present to clients, showing them the results. Naturally, we never make decisions independently—the client always has the final say on whether to implement changes.” – Luca Regazzo, Technical Sales Manager.