Reducing costs. This has been the most frequent request we've received from our clients over the past year. For many industrial companies, reducing business costs has become essential to remain competitive in the market. In a context where raw material prices constantly fluctuate and customers demand increasing flexibility and speed, many industrial groups are focusing on optimizing their production processes and supply chains.
However, in order to meet this need without compromising the quality and performance of the stainless steel semi-finished product, assembly, or component we produce, a thorough analysis of the project, processes, and production cycle is essential. Simply lowering the price is not enough - it’s necessary to find the right balance between economic, technical, production, and commercial requirements.
Managing the supply chain helps us understand how to reduce business costs
In the industrial sector, reducing costs means reviewing the design and rethinking the production process. That’s because the two factors that most affect the final cost are the processing costs and the type and amount of raw material used — stainless steel — a material subject to significant price fluctuations. To limit this impact, the project and its applications must first be assessed, with two possible approaches:
- reducing thicknesses to decrease material weight and, consequently, the impact of steel costs on total expenses
- choosing more cost-effective processing solutions
All of this must be done without compromising product quality and performance. Achieving this goal is nearly impossible without in-depth knowledge of raw materials, market dynamics, and available technologies.
This is why, at Metal’s, we have always invested in training, certifications, know-how, and the most innovative technologies — to be true partners to our clients, not just suppliers. Thanks to our extensive experience and the expertise of our technicians, we are able to manage the entire supply chain and identify where to act to reduce both costs and lead times, while maintaining the high quality standards agreed upon with the companies that choose us.
Reducing production and business costs: 8 Metal’s case studies
Here are 8 examples that show how we support our clients. Together, we identify solutions that allow us to maintain high performance while reducing production costs — and consequently, overall business costs — making the final price of their products more competitive.
1 – Reducing production costs for a bakery oven manufacturer
Recently, we responded to a request for production cost reduction from one of Metal’s long-standing clients, a company specialized in manufacturing bakery ovens. As always, we started with a detailed technical analysis of the project to identify where it was possible to reduce component thicknesses in order to lower the amount of material used and to find more cost-effective alternatives to welding.
Reducing thicknesses may seem simple, but it can compromise the structural tension and seal of the product once it reaches baking temperatures (200°C). We therefore suggested structural reinforcements and shape modifications, conducting specific tests to prevent deformation. At the same time, we replaced certain processes, reducing weld points and adjusting surface finishing steps. Finally, we redesigned the sheet metal covering: thicknesses, joints, and fastenings were all reworked to meet new design and cost requirements.
Price list reduction for a major Food Processing group
In this second case, another long-standing Metal’s client — a major international group specializing in meat packaging machinery — asked all suppliers, including us, to apply an 8% reduction on list prices. This was a challenging request, especially given the high number of items and the complexity of the product range we manufacture for this client, which includes hundreds, if not thousands, of active codes. To meet the challenge, we first grouped the items into homogeneous families and carried out a detailed cost analysis for each group. Then, we proposed a series of targeted measures: reducing thicknesses where feasible and replacing welding with alternative solutions such as bending, screw fastening, riveting, or custom interlocking systems. As a result, we not only met the client’s request — we exceeded it, achieving an average list price reduction of more than 8%.
3 – Reducing production costs for a Food & Beverage company while maintaining the product’s aesthetics to adapt it to different markets.
In this case, a major company in the Food & Beverage sector approached us with a specific need: to reduce the production costs of a beverage vending machine designed for the Middle Eastern market — without compromising the quality or visual appeal of the final product. The project involved several technical challenges, due to the presence of special components such as a large display and a refrigeration unit, both essential for meeting the needs of the target market.
We started by analyzing the product and its cost structure. This assessment enabled us to propose a number of cost-saving improvements: replacing welding with riveting to maintain structural integrity at a lower cost, introducing new functional bends to simplify assembly, and optimizing production through the use of dedicated molds and automation in the finishing stage. We conducted tests and developed prototypes to offer the client several options, all aligned with the original specifications. Thanks to these enhancements, we achieved a significant reduction in production costs without affecting the product’s aesthetics or performance.
4 – Optimizing the production of meat processing machines by minimizing handling errors
When we take on a project, we don’t just carry out what's requested — we study it in depth. If we identify areas for improvement, we proactively propose modifications to our clients. This approach applies even when production has already started.
That was the case with an international company in the Food Processing sector, which manufactures meat processing machines and approached us about an issue during assembly: The screws provided in the original design did not ensure correct fastening, leading to frequent rework and delivery delays. For the client, this meant costly waste. By carefully reviewing the project, our technical team identified a simple but effective solution: replacing the traditional screw fastening system with cage nuts. This improvement solved the issue and optimized production with predictable and controlled costs.
5 – A process change that enabled us to cut costs and production time for industrial fryers and ovens
Here’s another example of how costs can be reduced by minimizing production waste. In this case, we optimized the manufacturing process for one of Metal’s long-time clients, specialized in producing industrial fryers and ovens. Before our intervention, welding was performed manually — a skilled, but time-consuming and costly process. The client was looking to improve both the quality of the final product and production efficiency. We proposed switching to laser robotic welding, an automated process that is faster, more precise, and less expensive than manual welding, as it reduces material waste and lowers production costs.
6 – Optimizing costs, performance, and aesthetics through laser welding
Laser welding was at the core of another innovation proposed to a long-time Metal’s client in the Food Processing sector, also specialized in industrial fryers and rotisserie ovens, as in the previous case. In this instance, the client asked us to further optimize an already consolidated product: rotisserie ovens and fryers. Our technical team suggested switching from traditional manual welding to robotic laser welding, a process that offers higher precision and speed, keeps surfaces cleaner, and significantly reduces heat input, minimizing steel deformation and stress. We conducted a series of internal tests to verify joint quality and confirm the aesthetic, functional, and economic advantages of this technology. The results were remarkable: greatly improved precision, shorter processing times, reduced material waste - resulting in cost optimization - and an aesthetic improvement of over 70% compared to the previous process.
7 – Cost optimization in the production of cabinet systems for the baking industry
A few years ago, one of our clients asked us to optimize the production costs of their oven cabinets — without compromising aesthetics, strength, or functionality. It was a real challenge, and one we gladly accepted. We knew that these wheeled cabinets, used in environments with uneven floors, had to be both durable and lighter than previous models — while also being more cost-effective. Finding a way to reduce costs required an innovative approach. Our technical team proposed producing pre-assembled stainless steel cabinets. We introduced a custom-designed interlocking system and a new fastening method, maintaining varied thicknesses and materials based on technical and design needs. The result? A robust structure, aesthetically unchanged compared to previous models, with lower production costs.
8 – Simplifying the production of extractor hoods to reduce manufacturing and maintenance costs
When a solution aimed at reducing production costs also helps cut maintenance costs, the result is especially satisfying. That’s exactly what happened with a major client in the HO.RE.CA. sector, who entrusted us with the development of extraction components for ovens, with the goal of cutting costs. Our technical team analyzed the entire project — from individual components (wiring, electronic boxes, fans, exhaust pipes, condensation units) to assembly and maintenance procedures. We then proposed an improved solution that made it easier for water to drain, simplified the replacement of parts during maintenance, and reduced the number of welds. These improvements made the extraction units easier to assemble, clean, and service. Most importantly, they allowed for a reduction in both production costs — as initially requested — and maintenance costs.
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At Metal’s, we carefully select the clients we work with - medium to large-sized companies - and support them throughout every stage of the logistics flow: from concept to the creation of stainless steel assemblies, semi-finished products, and machine parts. Would you like to learn more?