Case Studies
Real Projects,
Measurable Results
How manufacturers across appliances, construction, and office products cut costs and scaled faster — with actual numbers, not marketing claims.
15+Years Manufacturing
40+Export Countries
200KTons Annual Capacity
500+Active Clients
🏠 Appliance Manufacturing
From painting lines to
pre-coated supply chains
Appliance manufacturers switched to pre-coated steel to eliminate in-house painting, cut defect rates, and hit colour consistency targets that spray lines can't reach.
01
Refrigerator Manufacturer
PCM Steel · PE Coating
The Problem
Running an in-house painting line for refrigerator panels. Colour variation reached ΔE 1.4 batch-to-batch — visible to consumers comparing units side by side in showrooms. Defect rate sat at 4.8%, meaning nearly 1 in 20 finished panels required rework or scrapping. At $200+ per finished unit, that added up fast.
Our Solution
Switched entirely to pre-coated PCM steel panels supplied direct from our coating line. Eliminated the in-house painting operation. Colour consistency controlled to ΔE ±0.4 across every coil, every batch.
ΔE 0.4
Colour consistency — down from ΔE 1.4. No more visible batch variation on the showroom floor.
0.3%
Defect rate — down from 4.8%. First-pass yield improved from 95.2% to 99.7%.
$2.1M
Equipment investment avoided. Production cycle shortened by 2 days.
Refrigerator Door PanelPCM steel, PE coating, ΔE ±0.4 colour control
Appliance Production LinePre-coated coils fed directly into stamping presses
Quality InspectionSurface uniformity checked before shipment
🏗️ Construction & Roofing
Faster envelopes,
no on-site painting
Pre-coated metal arrives coating-complete. No painting crew, no weather delays, no VOC permits — material is ready to install the moment it's on site.
02
E-Commerce Distribution Center
PPGI · SMP Coating · 0.50mm
The Problem
A major logistics company needed to complete a 35,000 m² warehouse envelope on a tight schedule in tropical conditions. The original plan included site painting — but humidity, monsoon risk, and VOC compliance made that approach costly and unpredictable.
Our Solution
Supplied 0.50mm PPGI with SMP coating in 45mm rib profile for roofing, plus 50mm PU sandwich panels for walls. All material arrived pre-finished — crews moved straight to installation with no priming, no topcoat, no cure time. See our guide on pre-finished metal for construction.
8 weeks
Full building envelope completed from first delivery to close-in.
12 days
Schedule saved versus site-painting — no weather delays, no coating downtime.
$30,000
Direct cost savings in painting labour, equipment, and site overhead.
SMP Coated Roofing0.50mm PPGI, 45mm rib profile, installed in tropical climate
Completed Envelope35,000 m² finished in 8 weeks from first delivery
On-Site InstallationNo painting crew, no drying time — straight to fixing
03
Warehouse Developer
PPGI · PE Coating · Wall Cladding
The Problem
A developer compared two approaches for wall cladding: Option A — install bare panels, prime and topcoat on site (18 working days). Option B — pre-finished panels installed directly. Site overhead was running $2,500 USD per day.
Our Solution
Supplied pre-coated wall cladding panels with PE coating, factory-finished and ready to fix on delivery. Installer crews went panel-by-panel with no wait states between trades — zero painting crews, zero coating materials on site, zero VOC permit delays.
6 days
Wall installation completed — versus 18 days for site-painting approach.
12 days
Schedule compression at $2,500/day site overhead.
$30K+
Total savings including overhead, painting labour, and materials.
Wall Cladding InstalledPE coated panels, factory-finished, fixed directly on arrival
Ready to InstallMaterial arrives coated, cut, and packaged for the site
Complete SystemMatching pre-finished gutters and trim — zero site painting
📋 Whiteboard & Office Products
Replacing enamel with
a smarter material model
Not every application needs the most durable material. Sometimes "good enough + affordable" unlocks a bigger market than "premium + expensive."
04
Whiteboard Manufacturer
White Pre-Coated Steel · Custom Surface
The Problem
Using enamel steel sheet as the writing surface — durable, but expensive. Finished whiteboards retailed for around $1,000 per unit. High price meant slow turnover, limited market penetration, and difficulty competing in price-sensitive segments across Southeast Asia.
Our Solution
Switched to white pre-coated steel with surface specs matched to whiteboard requirements — marker adhesion, clean erasure, gloss uniformity. Writing and erasing performance comparable to enamel in real-world use. Raw material cost: less than one-fifth of enamel steel. Learn more about coating types and surface specs.
<$200
New retail price per unit — down from ~$1,000. An 80%+ drop that opened mass-market segments.
80%+
Raw material cost reduction versus enamel steel, enabling price-competitive positioning.
↑ Repeat
Shorter lifespan (~1/3 of enamel) accelerated replacement cycles and increased purchase frequency.
Finished WhiteboardWhite pre-coated steel surface — marker adhesion and clean erasure confirmed
White Pre-Coated CoilCustom surface spec: gloss uniformity and hardness matched to writing requirements
Cost ComparisonPre-coated steel at <1/5 the price of enamel — same writing performance
A note on lifespan — and why that's actually fine
Our pre-coated steel whiteboard surface lasts roughly one-third as long as enamel. We're not hiding that. The point was never to replicate enamel — it was to build a product that performs well enough for most users, at a price that unlocks a much larger market. Shorter replacement cycles mean more frequent purchases. For the manufacturer, that translates directly into higher annual revenue. Different material model, different business logic — both valid.
What clients say
Switching to pre-coated panels eliminated our painting line entirely. The colour consistency is something we couldn't achieve with spray — our QC rejection rate dropped to almost nothing within the first month.
We were sceptical about the enamel replacement at first. But the writing surface performs exactly as described, and the price difference allowed us to enter markets we simply couldn't reach before.
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