Tupai , a leading name in the world of manufacturing, has become synonymous with quality, precision, and innovation. What sets them apart from other companies is their all-in-house manufacturing process , which ensures a high level of control and perfection at every stage of production.
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Raw Materials:
The Beginning of the Journey The manufacturing process at Tupai starts with cutting raw materials to size. This includes brass and zinc, which are used for the production of various products. Tupai explains, by cutting these materials to precise dimensions, Tupai ensures that the initial stage of production is seamless and accurate.
"We work mainly with brass products. We purchase the raw material from certified suppliers in Europe, and then we make all the transformation in-house."
Brass Products:
Hot Forging is used to mould the brass products, the raw materials are heated and hot forged. This process involves the application of heat and pressure to form the brass into the desired shape. The hot forging process results in products with superior strength, ductility, and an excellent surface finish.
Zinc Products:
Precision Dye Casting: The dye casting process is employed for zinc products. This involves pouring molten zinc into a mould, which is then allowed to solidify into the desired shape. The result is highly accurate and intricate products with exceptional dimensional accuracy.
In-House Tool Shop:
Crafting the essentials Tupai's commitment to quality extends to the creation of all tooling in their in-house tool shop. This allows them to maintain full control over the tools used in the manufacturing process, ensuring consistency and precision.
A perfect blend of skilled craftsmanship and advanced machinery, the tool shop is responsible for creating custom moulds, dyes, and punches that bring handle designs to life.
Once the handle design has been finalized, the Tupai in-house tooling shop swings into action to create the necessary tools for production. The manufacturing process relies on a combination of Computer Numerical Control (CNC) machines, lathes, mills, surface grinders, and precision wire-cutting tools to ensure the highest quality possible.
CNC Machines:
At the heart of the tool shop are the CNC machines, which allow for precise and efficient production. These versatile machines can perform various tasks, including cutting, drilling, and milling. Programmed with the finalized handle design, the CNC machines bring the idea to life with exceptional precision and repeatability.
Lathes and Mills:
Lathes and mills are essential tools in the prototyping process, responsible for shaping and finishing the final tooling. Lathes work by rotating the material against a cutting tool, while mills use rotary cutters to remove material. These machines, operated by skilled technicians, ensure that the final products are produced with the utmost accuracy.
Surface Grinders:
Surface grinders are crucial in achieving the perfect flat finish on injection moulding jigs. These machines use an abrasive wheel to create a smooth, polished surface on the moulds joining surfaces.
Precision Wire-Cutting Tools:
Precision wire-cutting tools are vital for creating the intricate cooling channels that are required to keep the moulds at the optimum temperature for dye casting. These tools use a thin, electrically charged wire to cut through the material with incredible accuracy. This allows the tool shop to produce jigs with complex designs.
Tupai's in-house tool shop is a testament to the company's commitment to quality and innovation. By combining the latest technology with the expertise of skilled technicians, the tool shop creates the custom molds, dyes, and punches necessary for producing exceptional handles. As a result, Tupai continues to be a leader in the industry, delivering handles that are not only aesthetically pleasing but also durable and functional.
"We have invested a lot into innovating our whole production, with specialist tools, robotics and using clearer energy."
Dedicated 3D C.A.D. Department:
Design and Innovation At the heart of Tupai's innovation lie its dedicated 3D C.A.D. department. Here, all product designs are produced and proven, which allows the company to continuously push the boundaries of what is possible in the manufacturing industry. Tupai notes,
"there's lot of artwork behind it until we put a new lever out in our catalogue, it probably takes, ten or twenty different versions until we think we have got it right, but in the end, the judge will always be the customer."
Polishing:
A Blend of Human and Robotic Expertise To achieve a flawless finish, products are polished using a combination of human and robotic polishing machines. This collaborative approach guarantees a perfect surface finish, striking a balance between efficiency and attention to detail.
Paint Application:
For paint products, paint is applied in a dust-free environment by a robot. This guarantees a consistent, high-quality finish. The products are then baked in an oven, resulting in a durable and long-lasting finish.
Advanced Quality Control:
Ensuring Excellence Throughout the manufacturing process, an advanced quality control system is in place to inspect products at every stage. Any minor defects are detected and rejected, with the materials then recycled to minimise waste. Tupai emphasises,
"We have a very strong quality control system. That means that in all the steps of the production process, we check the quality of the product, and we make sure that the product is according to our internal quality standards."
Assembly and Packaging:
Ready for Dispatch Finally, each handle is assembled and packed, ready for dispatch to the customer. This process ensures that every product leaving Tupai's manufacturing facility meets the company's exacting standards.
Conclusion:
Their eco-conscious approach to manufacturing, which includes recycling rejected materials and minimising waste, demonstrates Tupai's dedication to sustainable practices. This not only benefits the environment but also contributes to the long-term success and growth of the company. The owner of the company states, "Our quality control system also allows us to minimise waste. If we have a product that doesn't fit our quality standards, we will recycle it, and it will be used as raw material for other products."
In conclusion, Tupai's all-in-house manufacturing process is a shining example of what can be achieved when a company is committed to excellence, innovation, and sustainability. By maintaining control over every stage of production and continually investing in cutting-edge technology, Tupai sets the benchmark for quality and precision in the manufacturing world. This approach has positioned them as a leader in their field, providing customers with products that stand the test of time and deliver outstanding performance.
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