FROM STEEL
TO PRECISION
RADIATOR.
A rigorous, step-by-step manufacturing process that ensures every radiator meets the highest standards of quality, dimensional accuracy, and long-term reliability.
EIGHT STAGES.
ZERO COMPROMISE.
Every Tegra radiator passes through a carefully engineered sequence of manufacturing stages — each designed to build on the precision of the last. From the selection of raw material to the final packing, quality is never left to chance.
Our process conforms to IEEMA standards and is carried out on state-of-the-art special-purpose machines that deliver exceptional repeatability and dimensional accuracy.
ROLL
FORMING
- Grade D CRCA Steel sourced from reliable and approved suppliers. Standard thickness is 1 mm unless otherwise specified by the customer.
- Fins are cut to length on a special-purpose CNC roll forming machine with feedback control, engineered for precision and achieving accuracy of ± 0.01 mm — ensuring consistent fin profiles across every batch.
- A 24-flute fin design is used to maximise surface area for efficient cooling.
- The machine can form sheets up to 1.5 mm thick, accommodating a wide range of customer specifications.
SPOT
WELDING
- A gang spot welding machine — fitted with 5 pneumatically controlled heads — is used, enabling multiple welds simultaneously for significantly faster turnaround times.
- The weld pitch is maintained automatically at a consistent 50 mm, eliminating human variance and ensuring structural uniformity across every fin.
SEAM
WELDING
- Seam welding is performed manually using a robust 200 KVA Seam Welding Machine fitted with chillers for consistent cooling — delivering continuous, leak-proof welds along the full length of each fin.
- This critical stage seals each pressed fin pair, forming the enclosed oil-carrying channel that defines a radiator's thermal performance.
EASY
ASSEMBLY
- Specially designed assembly tables ensure a consistent 50 mm pitch between fins throughout the assembly process.
- Highly skilled professionals perform welding of fixtures including lugs and flanges with precision and care.
- Fin necks are MIG welded to 80 NB ERW header pipes.
- Dimensional accuracy of centre-to-centre length and skew is maintained within permissible limits.
PRESSURE
TESTING
- All radiators are hydraulically pressure tested at 2 kg/cm² for a minimum of 30 minutes to verify complete leak-proofness before proceeding to surface treatment.
- This ensures that every weld seam and joint is structurally sound and capable of withstanding the operating pressures of oil-immersed transformer service.
SURFACE
TREATMENT
A rigorous two-stage surface treatment process — internal coating and external painting — protects each radiator against corrosion, heat, and the harsh demands of outdoor transformer environments.
INTERNAL COATING
- Radiators are thoroughly cleaned using pressurised air to remove all manufacturing debris from internal channels.
- Internal surfaces are then flushed with Heat and Oil Resistant varnish or paint, ensuring long-term compatibility with transformer oil.
EXTERNAL COATING
Surface Preparation
- Degreasing and surface roughness of SA 2½ is achieved through grit blasting in a specialised booth, creating the ideal anchor profile for paint adhesion.
Painting
- All painting is done using the industry-standard flood coating process.
- Two or three-pack system using PU or Epoxy paint, applied as per customer requirement — including corrosivity categories C3 to C5.
- Paint shade, brand, and DFT as per customer specification. Standard DFT is 120 microns (60µ primer + 60µ topcoat) unless otherwise specified.
- Radiators are painted within 4 hours of shot blasting to prevent flash rusting and ensure optimal adhesion.
- Galvanising can also be carried out for radiators requiring additional corrosion protection.
FINAL
INSPECTION
A thorough visual and technical inspection by trained professionals ensures every radiator matches our set standards before dispatch — covering but not limited to the seven key areas below.
Paint Peel Off Test
Conducted per IEEMA: TR 25-DC using permacel tape on a batch basis, to ensure proper drying and adhesion is achieved before dispatch.
Dimensional Inspection
Centre-to-centre length and skew checked against permissible limits
Leak-Proofness Testing
Pressure tested up to 2 kg/cm² to verify complete seal integrity
Internal Cleanliness
Internal channels verified free from debris, scale, and weld spatter
Coating Thickness
DFT verified to ensure standard 120 microns or as-specified is achieved
Final Unit Inspection
Complete visual and dimensional sign-off by trained QA professionals
Visual Inspection
Checked for burrs and spatter across every unit before dispatch
PACKING &
DISPATCH
- Radiators are individually wrapped in 70-micron clear film before being packed in sturdy wooden crates.
- Standard packing format: two radiators per crate, interlocked by bracing straps on corners (Lug-to-Lug and Flange-to-Flange) using fasteners on 25 × 3 mm MS strips.
- Wooden batons — 40 mm wide with 4 mm thick foam padding — are placed between radiators to dampen shocks and vibration and eliminate damage to edges during transportation.
- The wooden packing is locked to the crate on all 4 sides using 3 mm straps, preventing any internal movement and ensuring radiators arrive in perfect condition at site.
- Crates are assembled in-house and can be scheduled to match the customer's packing requirements.
READY TO WORK
WITH US?
Let's discuss your radiator requirements. Our team will respond within 24 hours.