At Metal’s, we can carry out certified welding orders to meet our clients’ specific needs.
We have an extensive machine park, complete with automated systems that allow us to certify specific processes, as well as improve production and speed up operations to always meet agreed deadlines.
As your sole point of contact, we meticulously manage every detail and suggest actionable steps to optimize a project, both in terms of production and cost and logistics. One of our key goals is to streamline the entire process, making each phase increasingly sustainable, including transportation.
In this case study, we explain how we can provide you with welded semi-finished products and complex assemblies, complete with certification. We also highlight the advantages of a fully planned and organized system.
Certified welded products and meticulous logistics management: a Metal’s case history
Every project is realized after an evaluation by our technical department, even starting from an idea proposed by the client. This way, we can assess its production feasibility and identify any potential issues, all while maintaining an active and collaborative relationship. If necessary, we suggest possible improvements to reduce costs, improve production timelines, or ensure greater sustainability in transportation.
This was the case, for example, with a major client in the Food Processing sector who required a certified solution.
The case and the solution in brief: the need to eliminate gaps
A renowned German company with international distribution asked us to create an oven with sealed welding zones, free of gaps, in three different sizes.
The goal? To prevent the accumulation of cooking residues in hard-to-clean areas (such as the spaces between two components, corners, or small crevices that trigger material oxidation) and to extend the product’s lifespan.
Our proposal: targeted, certified robotic welding
To meet the buyer’s requests — including continuous production of around 6,000 units per year — we proposed a robotic internal welding process.This precise operation focuses on the functional areas of the oven components, allowing us to seal the gaps between the joints (i.e., the empty spaces that can form between parts, where dirt or cooking residues may accumulate).
Testing and prototypes for an excellent result
Before starting mass production, as with every project, tests and prototypes are necessary, carried out on the selected material (in this case, food-grade stainless steel). This allows us to meet the client’s requirements, fine-tuning processes, speeding them up, and avoiding waste.
For the production of gap-free ovens, in addition to a series of verification tests conducted at Metal’s, the client also independently performed external durability tests in a specialized laboratory. This allowed the client to simulate the product’s lifespan based on its intended use, considering factors such as operating conditions, saturation environment, humidity, and salinity.
Production launch
After passing the preliminary checks, we moved forward with the development of the entire industrialization phase. In this stage, we created the molds for the three different types of ovens, as well as the bending and welding equipment. Once the entire welding process configuration was set up, we focused on optimizing the cleaning process through pickling and localized passivation. The result? A smooth-surfaced product, capable of preventing contamination and featuring an additional protective anti-corrosion layer.
The importance of certifications
One of the key requirements for this project concerns certifications. At Metal’s, we hold both certifications for welding quality (EN ISO 3834-2:2021) and for welders (UNI EN ISO 9606-1:2017).
“In projects like these, with specific and detailed requirements, the testing and prototyping phase is essential to ensure that we’re on the right track. It takes time to develop the industrialization process, create the molds, the equipment, and configure the processes in the best possible way, improving production times and creating a perfect product. Even when the client has a clear vision of the goals to achieve, an external perspective can be useful to reach a better result. It’s a lengthy process in its initial stages, but one that must be refined in every aspect to meet the client’s demands, while also keeping an eye on sustainability.” – Luca Regazzo, Technical Sales Manager
Supply, warehouse, and logistics: a key element for an efficient and sustainable process
At Metal’s, we offer a complete supply chain management service, from raw material procurement to product shipment. In the context of sustainable management, those who rely on us as their sole point of contact can also count on the organization of supplies, warehouse, and transportation.
We contact suppliers to obtain the materials needed for production, prepare a safety stock, and coordinate with the client on deadlines for goods delivery, ensuring the supply chain remains active and can handle possible downtime or emergencies.
With this in mind – and to avoid overloading production – we manufacture semi-finished products well in advance, assembling them only as the agreed delivery date approaches. This allows us to work ahead of time, provide warehousing services for our clients, and ship on schedule.
We offer our expertise to find the right packaging to prevent product damage during container shipping or ground transportation. Additionally, we plan shipments by optimizing space (and the associated costs). To this end, we prefer to send products in full-load shipments, devising effective and sustainable solutions to reduce costs and waste, also considering safe material stacking.
Rapid solutions in case of emergencies
When it comes to transportation, it’s essential to consider that assemblies and semi-finished products are bulky yet very lightweight.
For the German client, we arranged shipments to Europe and China, proposing two different solutions. For Europe, we opted for a system of stacking two oven models within the same container. For storage in China, our technical department designed an attachment to be applied to the product to enable shipping three pieces instead of two in the same space.
This option had to be quickly replanned because the carrier provided different container measurements. Even in emergencies, just before a shipment, we quickly readjusted to reorganize the space and ensure the order was shipped on time, while making sure the goods were well-packaged and protected. This solution allowed us to minimize the number of shipments, reduce costs, and have a lower environmental impact.