CASE STUDY · COMMERCIAL
Frozen Brothers: Metal Cabinet for Vending Systems
A value-engineered metal cabinet for frozen beverage vending systems, refined to support more efficient fabrication and consistent repeat production.
- Value Engineering: Design refinements for cost and time savings
- Refined Finish: Concealed welds and less linishing
- Simplified Build: Reduced number of parts
- Repeat Production: More than 5,500 units produced to date
INDUSTRY
Food & Beverage Vending
PRODUCTS
Metal Vending Cabinets
SERVICES
Engineering & Fabrication
OUTCOME
5,500+ Units Produced
Background
A UK Metalwork Partner for Growing Vending Demand
Frozen Brothers provides frozen beverage and vending solutions, including dispensing systems that need purpose-designed metal cabinets. As the business grew, sourcing metalwork from outside the UK was becoming challenging because of supply-chain issues.
Frozen Brothers was looking for a UK metalwork subcontractor that could provide a more consistent and reliable supply. After reviewing JC Metalworks’ capabilities and capacity, the client selected the team to support improved consistency, shorter lead times and a high-quality, cost-effective cabinet.
The partnership got off to a strong start, with the purchase order arriving shortly after the first meeting.
Challenge
Move from Overseas Sourcing to a Consistent UK Supply Route
Frozen Brothers needed a dependable metalwork supply as demand for its vending systems grew. Outsourcing from outside the UK had introduced supply-chain challenges, so the project called for a UK subcontractor able to support consistency, product quality and a practical route into repeat production.
Supply Consistency
The client needed a reliable source of cabinets rather than continuing to manage the difficulties associated with overseas sourcing.
Capacity for Growth
As the business expanded, its supplier needed the capability and capacity to support ongoing requirements.
Cost and Lead-Time considerations
The cabinet needed to be produced through an approach that could support shorter lead times and cost-effective output, without compromising the required quality.
Solution
Reverse Engineering and Value Engineering the Cabinet
JC Metalworks reverse-engineered the cabinet, developed detailed production drawings and created a sample to the client’s exact specifications. An engineering evaluation then identified opportunities to reduce cost and production time. The revised, value-engineered sample incorporated design changes that were subsequently approved by Frozen Brothers.
01 · REVERSE ENGINEERING AND SAMPLE DEVELOPMENT
Turning the Existing Cabinet into a Defined Production Design
The reverse-engineering process established the information needed to prepare detailed drawings. A sample was then produced to meet the client’s requirements, giving the team a practical basis for evaluating the design and considering improvements before moving forward.
02 · WELD AND FINISH OPTIMISATION
A Cleaner Finish with Less Linishing
Design changes introduced concealed welds to provide a neater, more refined finish. The team also reduced the number of welds, which minimised the need for linishing and improved production efficiency.
03 · PART REDUCTION AND STABILITY
Simplifying the Build While Improving Stability
The value-engineering review reduced the number of parts in the cabinet. A welded cut-out was replaced with a punched form, and a brace bracket was added for stability. These changes helped make the cabinet stronger, more stable and more durable.
RESULTS
5,500+ Units Produced to Date
More than 5,500 units of the cabinet have been produced to date. The result reflects a value-engineering process that focused on a refined finish, fewer welds, a reduced part count and a design better suited to efficient production.
By working through the design with Frozen Brothers, JC Metalworks helped develop the original cabinet into an approved, repeat-produced solution while helping resolve the supply issues that led Frozen Brothers to seek a UK subcontractor.
5,500+ cabinets produced to date
Cleaner finish through concealed welds
Less finishing with fewer welds and reduced linishing
Fewer components through a reduced part count
Improved stability with a stronger, more durable design
Client approved value-engineered sample
At Frozen Brothers we love working with JC Metalworks. They are always on hand to give technical advice, communication is responsive and they consistently deliver quality products on time.
– Harriet Lally, Operations Manager.
FROZEN BROTHERS · METAL CABINET FOR VENDING SYSTEMS
A case study for procurement, engineering and product teams looking at reverse engineering, value engineering and repeat production of fabricated metal cabinets.
The download includes the project background, challenge, design refinements, equipment reference, result and customer testimonial.
