Header Shop / Manifold / System Tubing

Inside the Header Shop: Precision Manufacturing of HVAC Headers & System Tubing

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In high-performance HVAC systems, headers and system tubing are the critical arteries of thermal exchange. Balanced refrigerant flow, pressure stability, and lifetime leak-free performance depend entirely on the precision of these components.

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At MetaCool, our dedicated Header & System Tubing Division combines advanced CNC technology, premium raw materials, and elite craftsmanship to deliver headers that exceed both domestic OEM and international export-grade standards.

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World-Class Infrastructure & Balanced Capacity

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Our facility is equipped with specialized machinery sourced from the world’s leading engineering hubs. Our production line includes:

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• Precision Cutting & Bending: CNC Cut-to-Length and Multi-Axis CNC Bending machines.

• Advanced Shaping: CNC Hole Punching and Special Purpose Machines (SPMs) for swaging, spinning, and collar drawing.

• Assembly & Finishing: Specialized brazing stations, high-pressure leakage testing units, and industrial-grade washing systems.

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The MetaCool Advantage: Our installed capacity is meticulously balanced across all stages. This eliminates bottlenecks, ensures 100% machinery utilization, and prevents cost overruns—passing the efficiency and savings directly to our clients.

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Expert Human Capital

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Our division is powered by a highly skilled workforce with deep expertise in CNC programming and metallurgical processes. Every operator adheres to strict process discipline to ensure that complex designs are executed with zero deviation.

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Product Range

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We manufacture a comprehensive array of headers and system tubing in sizes ranging from 1/8” to 2-5/8”. Our products are designed to serve the most demanding coil shops and OEMs in India and overseas markets.

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Our Step-by-Step Manufacturing Excellence

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1. Premium Material Procurement & Traceability

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We utilize high-grade copper tubes, pipes, and brazing rods sourced from renowned global manufacturers. A key differentiator is our in-house brass component manufacturing, ensuring perfect compatibility. Every batch of raw material is tested and "tagged" upon arrival to ensure 100% traceability throughout the production cycle.

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2. CNC Pipe Cutting: Where Accuracy Begins

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Using CNC Cut-to-Length technology, we achieve exact tolerances with burr-free edges. This precision is foundational, ensuring perfect alignment during the subsequent bending and brazing stages.

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3. Hybrid Bending: Precision Meets Flexibility

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• CNC Bending: Utilized for standard and high-volume runs to ensure perfect repeatability.

• Manual Benders: Operated by expert craftsmen for complex, bespoke profiles.
  This hybrid approach allows us to efficiently handle both massive OEM contracts and specialized, low-volume custom designs.

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4. CNC Hole Punching & Collar Drawing

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Headers require perfectly aligned branch tube holes. Our automated punching and collar-drawing processes ensure:

• Optimal refrigerant flow dynamics.

• Stronger mechanical joints.

• Reduced stress on brazed connections.

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5. Spinning & Swaging

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Using dedicated PMT and drilling machines, we prepare tube ends for a perfect fit. This ensures superior mechanical bonding and drastically reduces the risk of leaks during the assembly phase.

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6. Certified Brazing Stations

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All assemblies are joined at dedicated stations by certified, specialist Brazers. We focus on uniform heat distribution and deep metallurgical bonding, which is essential for components that must withstand years of high-pressure HVAC cycles.

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7. 100% Leakage Testing & Final QA

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Reliability is non-negotiable.

• Pressure Testing: Every single assembly undergoes rigorous leakage testing to ensure zero micro-leaks.

• Final Audit: A comprehensive check of dimensions, brazing aesthetics, alignment, and internal cleanliness.
  Only after passing these stringent checks are the products cleaned, packed, and dispatched.

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Why Global HVAC OEMs & Coil Shops Choose MetaCool

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MetaCool is the partner of choice for manufacturers in India, the Middle East, and beyond because we offer:

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• Integrated Solutions: In-house brass and copper fabrication for seamless assembly.

• Scalability: Machinery and processes designed to handle high-volume OEM requirements.

• Export-Grade Quality: Consistency that meets the strict regulatory standards of global markets.

• Custom Engineering: Deep support for innovative and customized header designs.

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Conclusion

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At the MetaCool Header Shop, our machinery is more than equipment—it is a commitment to the HVAC industry’s evolving performance demands. From the first CNC cut to the final pressure test, every step we take is engineered to support the efficiency and longevity of your systems.

Precision at every joint. Reliability in every flow.

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