This case study highlights a long-term OEM cooperation with a leading air conditioner manufacturer in São Paulo. The client specializes in the production of split-type air conditioning units for both domestic and export markets across South America.
To support large-scale, automated manufacturing, the client required high-quality ASTM B280 C12200 copper pancake coils with strict consistency, cleanliness, and dimensional precision.
Project Background
Project Name: Split Air Conditioner OEM Production
Location: São Paulo
Client Type: Air Conditioner Manufacturer (OEM)
Application: Refrigerant tubing for indoor & outdoor AC units
Production Capacity: 500,000+ units annually
Material Requirements
| Parameter | Specification |
|---|---|
| Standard | ASTM B280 |
| Grade | C12200 (DHP Copper) |
| Size Range | 1/4" – 5/8" |
| Form | Pancake Coil |
| Temper | Soft Annealed |
| Annual Quantity | 120 Tons |
Customer Pain Points
As a high-volume manufacturer, the client faced strict quality control and production efficiency challenges, especially when dealing with inconsistent copper tube suppliers.
1. Inconsistent Quality in Bulk Supply
Previous suppliers failed to maintain uniform quality across batches.
Issues Observed:
Variations in wall thickness
Inconsistent coil lengths
Surface defects
Impact:
Machine calibration issues
Increased rejection rate
Production interruptions
2. Strict Cleanliness Requirement (ACR Standard)
For air conditioning systems, internal cleanliness is critical.
Problems with Previous Supply:
Residual oil contamination
Dust particles inside tubing
Oxidation due to poor sealing
Result:
Blockage in capillary tubes
Reduced cooling efficiency
Higher defect rate in finished AC units
3. Burrs & Poor Cutting Quality
The client required perfectly cut tube ends for automated assembly.
Previous Issues:
Burr formation at tube ends
Uneven cuts
Deformation during cutting
Consequences:
Damage to automated feeding systems
Poor brazing quality
Increased scrap rate
4. Incompatibility with Automated Production Lines
The manufacturer used fully automated tube processing systems, including:
Auto feeding
Auto cutting
Auto bending
Brazing lines
However, inconsistent tubing caused:
Machine jams
Misalignment
Reduced production speed
5. Supply Chain Instability
Delayed shipments
Lack of long-term planning
No OEM customization support
This made it difficult to maintain stable production schedules.
Our Solution: OEM-Grade ASTM B280 Copper Coil Supply System
To meet the client's requirements, we developed a customized OEM supply solution focusing on precision, cleanliness, and automation compatibility.
1. Long-Term OEM Supply Agreement
We established a stable annual supply contract (120 tons/year), ensuring:
Priority production scheduling
Consistent quality control standards
Reliable delivery timelines
2. Custom Pancake Coil Length
We provided customized coil lengths tailored to the client's production line.
Benefits:
Reduced material waste
Improved feeding efficiency
Optimized production cycle
3. Burr-Free Precision Cutting Technology
We implemented advanced cutting processes:
High-precision tooling
Controlled cutting speed
Post-cut edge treatment
Result:
Completely burr-free ends
Smooth tube edges
Perfect compatibility with automation
4. Ultra-Clean ACR Copper Tubing
All tubes were processed under strict cleanliness standards:
Degreasing
Nitrogen purging
Sealed packaging
Performance:
No internal contamination
Smooth refrigerant flow
Reduced system defects
5. Tight Dimensional Tolerance Control
We maintained:
Precise OD and wall thickness
Consistent coil geometry
Smooth surface finish
Impact:
Stable machine operation
Reduced calibration frequency
Improved production consistency
6. Automation Compatibility Optimization
We worked closely with the client's engineering team to ensure:
Coil tension consistency
Straightness during feeding
Compatibility with auto-bending machines
Implementation Process
Step 1: Factory Audit & Technical Alignment
We analyzed:
Production line requirements
Equipment specifications
Quality standards
Step 2: Sample Testing & Line Trial
The client conducted:
Automated feeding test
Cutting and bending test
Brazing quality inspection
Result:
100% compatibility achieved
No machine stoppages
Step 3: Pilot Supply (20 Tons)
Initial batch confirmed:
Stable production performance
Reduced defect rate
Improved efficiency
Step 4: Full OEM Supply (120 Tons/Year)
We began continuous supply with:
Monthly delivery schedule
Batch traceability
Full documentation
Project Results (Measured Impact)
1. Production Efficiency Increased by 25%
Due to:
Smooth automation process
Reduced machine downtime
Optimized coil design
2. Reduced Defect Rate in AC Units
Cleaner tubing → fewer system issues
Better brazing quality
Improved product reliability
3. Stable High-Volume Production
No supply interruptions
Consistent material quality
Improved production planning
4. Lower Operational Costs
Reduced scrap rate
Less machine maintenance
Fewer quality issues
5. Long-Term Strategic Partnership
Ongoing annual contract
Expansion to new product lines
Joint development projects
Why ASTM B280 Copper Coil is Ideal for AC Manufacturing
ASTM B280 copper tubing is specifically designed for:
Air conditioning systems
Refrigeration applications
OEM manufacturing
Key Advantages:
High thermal conductivity
Excellent formability
Clean internal surface
Strong brazing performance
Market Insights: Brazil HVAC Industry
In Brazil:
Growing demand for split AC units
Expansion of residential and commercial cooling markets
Increasing focus on energy efficiency
This drives demand for high-quality copper tubing in OEM manufacturing.
Key Takeaways for AC Manufacturers
✔ Consistency is Critical in OEM Supply
Even small variations can disrupt automation.
✔ Cleanliness Directly Affects Product Quality
Contaminants lead to system failure.
✔ Burr-Free Cutting is Essential
Especially for automated production lines.
✔ Supplier Stability Matters
Long-term cooperation ensures production continuity.
Global OEM Supply Capability
We support HVAC manufacturers worldwide:
ASTM B280 copper tubes
Pancake coils & straight lengths
Custom OEM solutions
Automated production compatibility
Export Markets:
South America
North America
Middle East
Southeast Asia
FAQ
Q1: What is pancake coil copper tubing?
It is soft copper tubing coiled flat for easy transport and automated processing.
Q2: Why is burr-free cutting important?
It prevents damage to equipment and ensures high-quality brazing.
Q3: Can you customize coil length?
Yes, based on your production requirements.
Q4: Do you support OEM branding?
Yes, including packaging and labeling.
Q5: Can your tubes work with automated lines?
Yes, they are optimized for full automation systems.
Contact Us
Looking for a reliable OEM copper tube supplier for your AC manufacturing?
Stable annual supply
High precision & cleanliness
OEM customization
Technical support
👉 Contact us today for samples and cooperation opportunities.
+8615769214734
office@dongmjd.com
