Production line and factory setup overview
A small/medium line assembling one non-pressure evacuated-tube solar water-heater family through stainless inner-tank and coated outer-shell sheet cutting, punching, rolling and longitudinal/seam joining, end-cover forming, port welding, pressure/leak inspection, concentric tank assembly, metered polyurethane insulation foaming and curing, collector-tube and frame fitting, hydraulic and thermal performance tests, cleaning, serial marking and protective packing.
Recommended lowest-entry line configuration Launch one 150-200 L non-pressure evacuated-tube model while buying certified vacuum tubes and prefabricated frames initially. Include tank sheet cutting/punching/rolling, TIG seam and port welding, end-cover tools, leak/pressure test, concentric foaming fixture with metered PU machine, assembly jigs and a thermal test rig. Pressurized enamel tanks and flat-plate collectors are separate technologies.
Production process and implementation sequence
- Sheet, tube and component release
- Inner/outer tank forming
- TIG seam and port welding
- Leak and proof-pressure inspection
- Concentric assembly and PU foaming
- Frame and evacuated-tube assembly
- Hydraulic and thermal testing
- Cleaning, serial marking and packing
Products, capacity and market fit
- Solar water heating reduces electricity and fuel use for homes and institutions.
- Local tank/assembly work can add value while critical tubes are imported.
- One tank volume controls jigs, ports, foam and packaging.
- Leak, insulation, stagnation and thermal-output tests determine safety and performance.
- Non-pressure evacuated-tube solar water heater - Tank volume, tube count, materials, insulation, leak/proof test, heat loss, thermal output, stagnation protection and frame - Afghan households, clinics, hotels and institutions
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Sheet shear, punch and rolling tools | Forms inner and outer tanks | 150-200 L model |
| TIG seam/port welding fixtures | Joins tank and connections | Weld procedure controlled |
| End-cover forming and assembly jigs | Controls geometry and concentricity | One diameter |
| Leak and proof-pressure test bench | Releases tank integrity | Every tank |
| Metered PU foaming machine/fixture | Forms uniform insulation | Density/fill controlled |
| Thermal/hydraulic test rig | Verifies heat loss and output | Named test method |
Raw materials, utilities and factory requirements
- Certified stainless inner-tank and coated outer-shell sheet
- Purchased evacuated tubes, seals and prefabricated frame parts
- Approved PU polyol/isocyanate insulation system
- Ports, valves, fasteners, labels, cartons and protective inserts
- Stable three-phase electricity with verified connected load
- Guarded machinery, lockout, ventilation and fire protection
- Dry segregated raw-material and finished-goods storage
- Maintenance tools, safe lifting and critical spare parts
- TIG shielding gas and welding fume extraction
- PU chemical store, metered ventilation and spill response
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Tank forming and welding equipment | US$28k-72k | One non-pressure model |
| Leak testing, PU foaming and jigs | US$22k-58k | Every-tank integrity |
| Assembly and thermal laboratory | US$16k-42k | Tubes/frames purchased |
| Freight, installation and spares | US$15k-38k | Pilot units included |
| Indicative installed low-entry total | US$81k-210k | Building, tubes, frames and working stock excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.