Processes

PROCESSES

Our manufacturing processes begin by eliciting customer requirements and producing engineering designs which will serve the basis for all subsequent processes. The components that we manufacture go through a wide range of processes conducted according to the engineering designs approved by our customers. The following are a general overview of our activities in the manufacturing facility before packaging and delivering the completed components to our customers. All our processes are strictly quality controlled using our in-house professional quality control personnel and we conform to ISO 9001 as well as environmental control under ISO 14001.

CUTTING & BUFFING

Tube cutting is a general process for most components before transitioning to further processes. Copper and other metallic parts that make up the components are precisely cut according to designs and buffed properly utilizing various industry standard and also in-house developed machines depending on measurement, accuracy and speed requirements. The following are the few types of the machines used:

CNC Straightening and Cutting Machine
Straight Tube Cutting Machine
Manual Cutting Machine
Semi-auto Buffing Machine
Manual Deburring Machine

BEADING & DIMPLING

Tube beading and dimpling can be applied to components to act as a stopper or to be used for clamping components together at consistent measurements. They are modifications made to the tubes to serve various purpose for the final component assembly and further application. We perform beading and dimpling for a wide range of measurement requirements by using precision machines and also manual tools if required.

EXPANDING & SWAGING

Expanding and swaging are processes performed for facilitating brazing of components or tubes together and they help to regulate fluid or air pressure as per requirement. We provide a wide range of measurements at which tubes are expanded or swaged and at which points on the tubes. These processes are also needed to connect copper tubes to the compressor unit when the connection diameter differs. The expanded or swaged components can be brazed using reducers or without using any additional components.

BENDING & COILING

These processes as the name suggests are performed to alter the flow of direction of the tube or to be used for cooling processes respectively. The measurements including the angle and the bending points are decided using the engineering specs conforming to customer requirements. The types of machines used for these processes include:

CNC Bending and Coiling Machine
NC Bending Machine
Manual Bending and Coiling Machine

PUNCHING, STAMPING & DRILLING

Punching and stamping processes are required to make precise holes at specific points on the tubes or components according to designs. Punching can be done for low volume tubes whereas stamping speeds up the process for high volume orders by using custom made dyes. Punching is also used for making copper caps for closing tube ends. For certain extreme requirements such as tube end hole-cutting, the drilling machine suits the task.

FLARING, COLLARING & END-FORMING

These processes are conducted depending on the requirements of the individual components and they require high precision machines. The flaring process is performed to basically prevent leakage at the connection points between tubes whereas the collaring process strengthens the joining points and allows for connector-less joints. We also perform full-close or half-close end-forming for certain tube types if the requirements dictates that.

BRAZING & ASSEMBLY

The individual components that have gone through several of the processes above will be brazed and assembled at this point to make the final completed component. Most of them are brazed manually using brazing torches due to unique specifications and high attachment quality requirements. The completed components are also leak tested before proceeding to the next stage.

WASHING, PACKING & DELIVERY

The final process will be to wash and polish the components for both functional and aesthetic reasons. The washing process involves the use of chemicals to remove grease on components which are properly disposed using disposal services conforming to ISO:14001. The packaging process depends completely on customer requirements and how they will want to receive their products as each customers have unique needs. We do deliver by lorries and containers within peninsular Malaysia and export via ship or air freights.