Case Study: Boosting Production Efficiency with Induction Brazing Equipment
June 12, 2025
In early 2024, a heavy equipment manufacturer from Southeast Asia approached TY INDUCTION with a problem: their existing flame-based brazing system was causing inconsistent joints, high operator dependence, and excessive energy consumption. The company specializes in manufacturing heavy equipment for construction and mining.
Facing increasing demand from market, the company needed a faster, cleaner, and more repeatable brazing solution to:
· Reduce defect rates
· Shorten brazing cycle time
· Minimize operator error
· Improve workplace safety
The client had tried automation solutions before, but the complexity of their assemblies—often a mix of aluminum, copper, and steel—combined with tight joint tolerances made it difficult to ensure repeatable quality.
The main pain points were:
· Inconsistent heating with flame-based torches
· High dependency on operator skill
· Slow cycle times (average 90 seconds per part)
· Excessive energy usage, with little control
· Lack of fume control and overheating risks in confined workspaces
After an on-site audit and part evaluation, TY INDUCTION recommended a custom-built Induction Brazing System equipped with:
· High-frequency power supply (300–500 kHz) for optimal precision on copper and aluminum
· Customized induction coils matched to each joint geometry
· Pneumatic coil positioning and clamping fixtures for repeatable alignment
· PLC + HMI interface for process control, monitoring, and recipe storage
· Optional fume extraction integration for improved operator safety
Our engineering team conducted heating simulations, and trial runs at our test facility in China, which demonstrated a 45% reduction in cycle time and 100% brazing consistency across multiple joint types.
The client sent 10 sample assemblies for heat profile testing. TY INDUCTION simulated multiple joint types under real conditions, optimizing:
· Coil geometry
· Power output
· Heating duration
· Brazing filler flow control
Result: Achieved strong, void-free joints with complete capillary action and no discoloration or oxidation.
We delivered a turnkey system within 8 weeks, including:
· Power source
· Control panel
· Coil fixtures
· Training and documentation in English
A local partner in Stuttgart assisted with on-site setup and technician training.
The machine was integrated into the client's semi-automated line, replacing two flame stations. With the induction brazing system:
· Each brazing cycle was reduced from 90 seconds to 48 seconds
· Operator involvement was cut by 60%
· Defect rates dropped from 4.8% to less than 0.5%
Metric | Before TY INDUCTION | After TY INDUCTION |
Brazing Cycle Time | 90 seconds | 48 seconds |
Joint Defect Rate | 4.8% | 0.5% |
Energy Use per Cycle | ~1.2 kWh | ~0.6 kWh |
Operator Involvement | High | Minimal |
Workplace Heat & Fumes | Significant | Negligible |
TY INDUCTION has become a trusted supplier for heavy equipment manufacturers across Asia, especially in:
· Malaysia
· Indonesia
· Thailand
· Vietnam
· India
· Parkistan
Asian procurement teams value:
· Customization for diverse part geometries
· Energy-efficient design aligned with Green Deal goals
· Process stability, repeatability, and automation readiness
· Remote and local support partnerships across Europe
"With TY INDUCTION’s brazing system, we were able to double our output while improving joint quality. The automation features allowed us to train new operators quickly, and the energy savings help with our sustainability targets. It’s a win across the board."
— Production Manager from one of our clients
Final Thoughts
For any company manufacturing heavy machineries, flame brazing is quickly becoming obsolete. Induction brazing offers a controlled, clean, and cost-effective solution—and TY INDUCTION has the proven track record to help you make the transition successfully.
Looking to Modernize Your Brazing Line?
Let TY INDUCTION help you:
· Reduce defects and rework
· Improve brazing speed and consistency
· Lower your energy and labor costs
Custom solutions. Fast delivery. Global support.
Contact TY INDUCTION today for a free consultation or sample heating test.
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