Product
Custom Galvanized Steel (GTC) pipes for commercial HVAC units, galvanized only on the exterior surface.
Customer
A leading UAE-based commercial HVAC systems manufacturer with an annual revenue of over $7.5 million.
Volumes
60,000 pipes per year (FOB approx. $0.55M USD), delivered in two large batches.
Achieved
38% reduction in purchase price Elimination of a hazardous process Significant time savings in assembly
Before Buying Office Asia
A Dangerous and Inefficient Production Bottleneck.
The client, a prominent HVAC manufacturer, faced a critical and unique production challenge. Their systems required steel pipes with rust-proof galvanization on the outside, but the standard pipes available on the market were galvanized on both the inside and outside. The internal galvanization layer reacted negatively with the refrigerant gas, causing blockages and system failures over time.
To solve this, they were forced to perform a dangerous, time-consuming, and costly chemical process in-house to strip the galvanization from the inside of every single pipe, a process which still sometimes left residue.
Hazardous Chemical Process
The process of chemically removing the internal galvanization layer exposed their staff to dangerous materials and created safety risks.
Production Inefficiency
This extra stripping step created a major bottleneck in their assembly line, was very time-consuming, and slowed down their overall production capacity.
Quality Issues
Even after the chemical treatment, leftover galvanization residue could react with refrigerant gas, leading to clogged pipes and potential field failures.
No Existing Market Solution
Despite extensive searching, no supplier in the local or international market was able to provide pipes with galvanization only on the exterior layer.
With Buying Office Asia
Engineering a Custom Manufacturing Solution
Buying Office Asia was engaged to solve this complex technical and sourcing problem. We developed a completely new manufacturing process with a partner factory, establishing a reliable source of custom-made pipes with full quality assurance.
Step 1 / February 2023
Problem Identification & Technical Analysis
We began with a deep dive into the client's existing process, identifying all the chemical, safety, and quality issues. Our procurement engineers then established the precise technical requirements for the ideal pipe.
Step 2 / March 2023
Designing a New Manufacturing Method
Our engineering team designed a novel production method to manufacture the pipes without any galvanization on the interior surface, creating a detailed technical plan to present to potential manufacturing partners.
Step 3 / April 2023
Sourcing & Pre-Selecting Specialist Suppliers
With the new technical plan, we started sourcing potential partners. We identified and pre-selected five advanced steel pipe manufacturers who showed interest and possessed the technical capability to develop this new production method with us.
Step 4 / May 2023
Negotiation & Partnership Development
We entered into detailed technical and commercial negotiations with the shortlisted manufacturers. We focused on finding a partner who was not just capable, but also willing to co-develop and invest in the new process.
Step 5 / June 2023
Supplier Selection & Successful Test Batch
We secured the best overall deal from one highly cooperative supplier. Together, we produced an initial test batch to prove the viability of the new manufacturing method and to verify the quality of the final product. The tests were a complete success.
Step 6 / September 2023
Scaling to First Large-Scale Production
Following the successful test, we placed an order for the first large batch of 15,000 pipes, enough to cover the client's quarterly needs. Rigorous quality control was implemented to ensure every pipe met the new, exact specifications.
Step 7
Ongoing Establishing a Continuous, Reliable Supply
With the new production method perfected, we established a long-term plan for two large production batches per year. BOA now handles the entire process for the client, including quality control for every batch and transparent reporting, functioning just like their own expert team in China.
Share Your InquiryA Word From Our Customer
"BOA solved a critical manufacturing bottleneck for us by finding a factory that could produce pipes to our exact technical specifications. This eliminated a hazardous internal process and cut our component costs by nearly 40%."
Faisal, Head of Procurement & Production
Commercial HVAC Systems Manufacturer
The Strategic Impact:
Beyond the Solution
This partnership delivered far more than just a custom component; it transformed the client's operational safety, efficiency, and long-term competitiveness.
Enhanced Safety & Operational Streamlining:
By eliminating the hazardous internal chemical stripping process, we significantly improved worker safety and removed a major bottleneck. This dramatically streamlined customer’s production, freeing up valuable time and resources.
Unlocking Profitability
& Efficiency:
The 38% reduction in component costs directly boosted the client's profit margins after all costs. This was achieved by not only finding a more efficient source but by designing a component that no longer required costly and time-consuming in-house modification.
A Unique, Competitive
Advantage:
BOA didn't just source a part; we co-developed a unique manufacturing solution. This gives the client an exclusive component unavailable to competitors, improving their product's reliability and performance.
Reliable, Continuous
Partnership:
Beyond the initial project, BOA remains the client's dedicated procurement partner. We ensure a consistent flow of high-quality, custom pipes, managing all QC and logistics. The client simply places an order, trusting BOA to handle everything transparently and efficiently, as if it were their own expert team on the ground.
Sourcing Custom Pipes:
Profitable, Safe, and Seamless.
Reduction in Component Costs.
Enhanced Safety
Eliminated Hazardous Internal Process.
Custom Solution
Unique, Market-Exclusive Component.
