Spare Parts Ckd Skd For Home Refrigerator

A Kit Is Not A Box Of Spare Parts. It Is A Production Line In A Container.

Every kit is built against a bill of materials for one cabinet size, then packed in the order your team will use it. Panels come out first, then the liner, then doors, then the sealed refrigeration parts, then the bag of fasteners for that unit. Nothing is bulk-tipped into the container, because a mixed pile is what turns a two-week build into a two-month one.

The same pack ships with a process sheet for each station, a torque and clearance sheet, and the refrigerant charge table for the model range you ordered. None of that is secret. It is simply the difference between buying parts and buying a method.

Everything In One Frame, Because That Is How Your Team Learns

A kit is checked twice: once as a bill of materials, once as a physical pack. Panels are counted by hand, doors are opened and re-taped, and the sealed parts are logged by serial number before the crate is closed. When the crate reaches you, the pack list is inside the lid, in the order the stations use it.

Missing parts are the single most expensive thing in a start-up factory, because a missing gasket stops a whole cabinet. That is why the pack carries a spare allowance on the low-cost consumables and why every kit is photographed before it leaves.

Site and layout

We start with a drawing of your building, not a catalogue. Door width, ceiling height, power entry, water, drainage, and where finished units will stand without being moved twice. A first line fits inside 800 to 2,000 square metres, including the foaming bay, the charging bench and the packing area, with room for a second line later.

Tooling list and power audit

The kit is the material; the tooling is what turns it into a product. Foaming fixtures, a vacuum pump, a charging station, a press brake, a spot welder, a leak detector and enough roller conveyor to move a cabinet without lifting it. The list ships with ratings, so your electrician can price the supply before the container sails. Around 20 kW of stable power plus a generator is the usual starting point, and 380 V three-phase is preferred because the vacuum pump and the bending machine run more reliably on it.

Before The Foam, It Is Only Folded Steel

This is what a cabinet looks like at the halfway point: sides folded and joined, liner in, wiring laid into the wall, no insulation and no door. Everything downstream depends on this station being square. A cabinet that is two millimetres out of square will fight the door for the rest of its life.

We teach the diagonal check and the gap check before we teach anything else, because both can be done with a tape measure and both catch the mistakes that no test at the end will fix.

The first kit order

Kits are quoted per model and per container. Start with one model and one container: training a team on a single cabinet is far easier than training it on five. The first order is also where the local identity is fixed, panel colour, handle style, badge, manual language, plug type, voltage and refrigerant.

Unpacking and staging

A kit has a right unpacking order. Panels into the rack, doors left wrapped, sealed refrigeration parts into a locked cage, fasteners into station bins sorted by unit. The pack list in the lid is the map, and the photograph we take before loading is the reference when something looks short.

One Sheet, Two Folds, One Correct Angle

Panels arrive cut and notched. Bending is the first place a new team loses time, because a fold that is one degree open will not close at the corner block. The press brake settings travel with the kit, written per panel, not per machine.

This is also where the steel specification matters. Our cabinets use 0.40 mm outer steel and 0.32 mm inner liner, against the 0.35 mm and 0.26 mm that most factories use. Thicker steel bends predictably and holds a corner, which is exactly what a hand-built cabinet needs.

Cabinet pre-assembly

Sides, top, bottom and back are folded and joined on a flat table, squareness checked at the diagonal, then the liner goes in and the harness is laid into the wall before the cabinet is closed. This is the station where an untrained team shows first, so it is the first one we stand at.

Foaming

The cabinet goes into the fixture, the injection gun fills the wall cavity, and the fixture holds the shape while the foam rises. Foam quality is a temperature story: our own plant runs a 20-23 deg C foaming room for a reason, and the same discipline applies in yours. Insulation is 65 mm, 85 mm or 110 mm depending on the model and the climate the unit is sold into.

Foam Is Where A Kit Becomes A Product

A foaming fixture is a steel cage with a hydraulic or manual clamp and a set of pins that locate the cabinet at the exact height of the injection port. It is the heaviest item on the tooling list and the one most often under-specified, because a loose fixture produces a cabinet with a bulge that no amount of trimming hides.

Fixtures are built for the cabinet family you order and shipped with the kit. If you add a second cabinet size later, you add a fixture, not a second line.

Refrigeration circuit

Nitrogen purge before brazing, so no oxide flakes travel into the capillary. Compressor, condenser, filter drier and evaporator are joined in the order the process sheet shows, and every joint is checked by eye before it disappears behind a panel. Our condenser tubing is 6.0 mm copper against the 4.78 mm used by most factories, with 120 denser wires on the 208 cabinet, which is why the same compressor runs cooler here.

Evacuation and charging

Vacuum to 20 Pa or better, hold, then charge by weight from the table for that model. A deep vacuum is not a formality: moisture left in the circuit is the most common cause of a capillary blocked in month three, and it is invisible until it happens.

Charge By Weight, Test By Curve

Charging is the only station where a small error looks like success. Half a gram too little and the freezer still reaches temperature in a cool workshop and fails in a hot shop. So the charge table is per model, the scale is calibrated, and the unit is judged on the pull-down curve rather than on a single thermometer reading.

Every unit gets a static leak test and an operating leak test. Our own plant uses INFICON detectors on both passes; the same pass and fail limits ship with the kit.

Electrical and controls

The harness plugs into the controller, the thermostat goes into its pocket, fan and light are connected, and earth is checked with a meter rather than by eye. On solar direct-drive builds the DC controller replaces the mains controller, and the 10 V to 50 V wide input is what lets a panel array drive the compressor without an inverter.

Leak test and cool-down

Static leak test first, then an operating leak test with the unit running, then a cool-down run long enough to see the curve flatten. A cabinet is signed off by the person who tested it, on a sheet that stays with the serial number.

Move The Cabinet, Not The Person

Roller conveyor is the cheapest productivity you will ever buy. One line down the middle with stations on both sides means a cabinet travels three metres between foaming and charging instead of being lifted by four people and set down crooked.

Layouts are drawn for the tools you actually own, not for an ideal factory. If the budget only covers conveyor between two stations, the drawing shows exactly those two, and the rest is added in the second year.

Packing and local branding

Protective film off, badge on, manual in the language you sell in, carton printed with your name and your model code. A locally assembled cabinet should read as locally owned, not as an import in a different box.

Ramp-up and after-sales

The first month is about repeatability: same torque, same charge, same test result, every unit. Our engineer stays for the training window and comes back every year to look at yield, rework and field returns with your team, because a factory that stops improving starts losing to the one that does not.

The Same Container That Brought Parts Takes Out Cabinets

Once the line runs, outbound packing matters as much as inbound. Units are stacked by model, corners protected, doors taped shut, and the load is planned so the first unit off the truck is the first one the dealer asked for.

Buyers who start with kits usually end up shipping to neighbours within two years. That is the point of building a line rather than a warehouse.

Six Machines, One Bench, One Cage

A first line does not need a machine shop. It needs the six items below, a charging bench and a locked cage for compressors and sealed parts. Everything on the list can be sourced locally or shipped with the kit, and the ratings are written so a local electrician can wire it without translation.

Roller conveyor is optional in year one and close to essential in year two, once two people are moving cabinets instead of building them.

One Engineer, Fifteen To Twenty Days, Then Every Year

A single engineer travels with the first kit. Fifteen to twenty days on site covers unpacking, the first cabinet built station by station, the first foaming run, the first charge and the first full test. After that the line belongs to your team.

The annual visit is not a courtesy. It is where yield, rework and field returns get looked at with fresh eyes, and where process improvements from our own plant get handed over before they become obsolete.

Our Own Line Is The First Reference

Every fixture, tooling list and process sheet in a kit exists because it is already running in our own plant. Cabinet steel, foam room temperature, evacuation limits and leak test method were not written for export; they were written for our own output and then packed into a container.

That matters when something goes wrong 6,000 km away, because the answer is usually a number we already know rather than a theory we have to test.

A Shop That Stocks What It Can Repair

The commercial point of a local line is not patriotism, it is lead time. A dealer who can replace a door gasket or a thermostat from stock keeps a customer; one who has to wait for a container loses them to the brand next door.

That is why the same kit programme covers spare parts as a standing item, not as an afterthought. Once the line runs, panels, doors, gaskets, compressors and controllers can be ordered on their own, in the quantities a service network actually uses.