CONTEXT
In the metalworking industry, there are projects in which the reliability of the connection between components is no longer merely one stage of the process, but becomes a critical performance factor. This was precisely the context of the project developed by ETMA for a leading multinational industrial group operating in the sector of equipment for domestic hot water systems — water heaters and heat pumps — and climate control systems, namely air conditioning.
ETMA was challenged to ensure the production of bespoke tubular metal components, developed for each specific appliance, with the purpose of guaranteeing the connection to the gas supply, while meeting demanding requirements in terms of leak-tightness, corrosion resistance and dimensional control.
The response was framed within ETMA’s “From Project to Product” approach, supported by its unique system of 10 Integrated Production Processes. This model enables different technologies and production stages to be combined within the same industrial logic, ensuring greater process control, increased adaptability and closer technical monitoring throughout the project life cycle.
CHALLENGE
The main challenge of this project did not lie solely in the geometry of the components, but in the need to combine industrial production pace, dimensional consistency and full leak-tightness in an application with particularly demanding functional requirements. As these components ensure the conveyance of gas, any dimensional variation during assembly or in the joining of the components would have a direct impact on the conformity of the final product.
The technical difficulty became even more evident in the joining process. Brazing played a central role here, as this is the operation that ensures the leak-tightness of the part. When the process is not stabilised, the number of rejections in leak-tightness tests increases, scrap levels rise and the ability to meet deadlines with robustness is reduced. It was therefore necessary to work on the process with a simultaneous focus on repeatability, control and production efficiency.
ETMA’S RESPONSE
ETMA joined this project when it was already at the series production stage, as part of an industrial transfer, which required rapid adaptability, process know-how and a highly objective assessment of the critical points to be stabilised. To ensure this transition, adaptations to the process were implemented, and improvements are currently under way aimed at increasing capacity, improving production pace and achieving greater operational robustness.
In this context, ETMA did not simply absorb an existing process. It carried out its industrialisation based on the know-how already acquired in furnace technologies and similar processes, strengthening its ability to transform the client’s production requirement into a more stable, controlled solution, ready to evolve. This rationale is aligned with the way the company presents its most recent projects: not merely as the production of parts, but as the industrialisation of technical solutions with predictability.
PROCESSES INVOLVED
From a production standpoint, this project is linked to several processes within ETMA’s system, particularly:
- Stamping, for the production of base components;
- Surface Treatments, to meet corrosion resistance requirements;
- Assembly / Welding, where brazing is integrated as a critical joining operation;
- Inspection, through a demanding control plan focused on functional conformity.
In the medium term, ETMA expects to further strengthen this integrated approach through other complementary operations, namely in the field of electroplating finishes and turning, increasing overall control over the project’s value chain.
BRAZING: THE KEY TO LEAK-TIGHTNESS AND CONSISTENCY
Brazing was the decisive process in the success of this project. More than simply joining components, it was necessary to ensure a precise, repeatable and leak-tight joint, capable of meeting the functional requirements of a gas-carrying application. In a part with this level of criticality, the choice of joining process cannot depend solely on production feasibility; it must also meet criteria of safety, dimensional stability and reliability in series production.
This is precisely where brazing adds value. Integrated into assembly operations, it enables the joining of small and medium-sized metal components with a high level of precision, making it particularly suitable for subassemblies with leak-tightness requirements, such as gas tubes, hydraulic systems or high-pressure applications. At ETMA, this operation falls within the Assembly / Welding area, which integrates solutions and systems prepared to meet demanding industrial contexts.
In this project, the transfer to ETMA was facilitated by the company’s existing know-how in furnace technology and by a solid technical foundation in this type of equipment. This made it possible to accelerate process stabilisation and create the conditions for a more robust industrial response, with lower risk of variability and greater control over the final results.
QUALITY
As would be expected in a component of this nature, quality control was structured according to particularly demanding criteria. The validation plan included 100% leak-tightness testing, dimensional control, 100% thread verification, salt spray testing and visual inspection, as well as the submission of an ISIR — Initial Sample Inspection Report — ensuring the technical conformity required by the client.
At an initial stage, ETMA chose to implement 100% inspection, precisely to ensure process stabilisation and reduce industrial risk. As process robustness becomes consolidated, the natural evolution will be towards a sampling-based control model, without compromising the required reliability standards. It is that old industrial maxim: first, you turn off the variability tap; only then can optimisation be discussed.
PRODUCTIVE ROBUSTNESS IN MEDIUM AND LARGE SERIES
This is not a low-volume project, nor a one-off production operation. It is an operation with an annual volume of around 500,000 parts, continuous production, albeit with varied references, automation requirements and a dedicated line. This context confirms ETMA’s ability to respond to projects with real industrial scale, while maintaining control over quality, production pace and repeatability.
VALUE FOR THE CLIENT
From the client’s perspective, the main objective was clear: to increase internal production capacity, freeing up resources and lines for other industrial requirements.The partnership with ETMA made it possible to meet this objective without compromising the functional performance of the product, ensuring continuity of supply and the conformity of a critical part within the final assembly.
Although, in the initial phase, there was no direct logistical gain or immediate reduction in the number of suppliers, the project creates a basis for that evolution in the medium term. More importantly, it consolidated a close technical relationship between ETMA and the client, focused on continuous improvement, increased efficiency and the reinforcement of installed production capacity.
WHY ETMA?
This case study highlights the difference between manufacturing a part and taking industrial responsibility for a critical process. ETMA does not contribute production capacity alone; it brings technical know-how, adaptability, process integration and a monitoring approach consistent with its “From Project to Product” methodology.
In a project where brazing is decisive to the function of the part, the competitive advantage lies in the ability to bring together process, control, production pace and continuous improvement within a single industrial response. And it is precisely this integration capability that sets ETMA apart: reducing complexity, increasing predictability and industrialising with confidence.
CONCLUSION
The introduction of brazing into ETMA’s portfolio strengthens the company’s ability to respond to metal subassemblies with demanding precision and leak-tightness requirements. In this particular project, the combination of process know-how, rigorous control, production integration and industrial scale made it possible to transform a critical operation into a robust solution, ready for series production.
For clients looking for more than a supplier — looking for a partner capable of industrialising critical components with rigour, reliability and a long-term vision — this project is a clear example of the added value ETMA can bring to the table.
If the challenge involves joining components with precision, controlling leak-tightness and ensuring consistency at volume, ETMA is prepared to take it from project to product. Talk to us and discover how we can support your next project.