For the past 25 years, ITW’s Tientai Electrode division has provided efficient and reliable welding solutions in the Chinese market across various industries, such as shipbuilding, offshore engineering, energy storage and transportation, and large-scale steel structures.

We spoke with the team to understand how they used ITW’s Customer-Back Innovation (CBI) Framework to develop new technology in the welding industry.

Increasing Demand for Low-Temperature Gas Transport

China's growing petrochemical industry and diverse global energy needs boosted demand for low-temperature gas transport. Key materials like ethane and ethylene, which were once imported, are now produced locally and exported, driving a surge in Very Large Ethane/Ethylene Carrier (VLEC) construction.

Despite the growing demand and years of application, traditional welding techniques for Low-Temperature Ethylene Gas (LEG) Tanks still present significant challenges:

Low Welding Efficiency: The construction of LEG tanks primarily uses 5% nickel steel plates welded with nickel-based manual arc welding rods, leading to low construction efficiency.
High Manufacturing Costs: Nickel-based manual welding rods are predominantly supplied by imported brands. These products are not only expensive but also have long lead times, exacerbating cost pressures.
Inconsistent Weld Quality: Manual arc welding heavily depends on highly skilled welders. Additionally, weld seams are prone to defects, posing safety risks for storage tanks operating under extremely low temperatures and significantly affecting the product lifespan.

Developing New Solutions

Guided by ITW’s CBI Framework, the division began efforts to solve customer pain points. Jay Fan, Innovation Director of ITW Welding Greater China, stated: “From the top down, the entire company was fully committed to this CBI project. We understood the importance of agility in innovation.”

The first step in the process was to communicate directly with the end-user. Tranjohn Quan, Sales Director of Tientai Electrode, said: “Close communication with customers enables us to identify key challenges and to develop innovative solutions, allocate resources effectively, improve efficiency, and uncover opportunities for innovation.”

After carefully observing their “80” customers’ welding operations, Tientai Electrode proposed replacing manual arc welding with automated flux-cored wire welding and switching from nickel-based to austenitic stainless-steel materials. To develop these new flux-cored wires, the division worked closely with their consumers to conduct pilot tests, provide on-site support, and train welders.

After launching the product, the new process boosted efficiency, improved quality, and limited material waste. Additionally, the innovative flux-cored wire technology created substantial value for consumers by:

Tripling Efficiency: The new flux-cored wire enabled customers to triple their annual construction capacity for Low-Temperature Ethylene Gas (LEG) tanks, helping clients meet the rapidly growing market demand.
Reducing Costs: The overall welding cost dropped by 30%, primarily due to reduced material expenses, decreased welding spatter, and improved material utilization rates.
Enhancing Welding Quality: The optimized flux-cored wire and process ensured uniform welds, reducing defects and enhancing storage tank safety under extremely low temperatures. It also lessened reliance on skilled welders, addressing workforce challenges.

Ling Song, Vice President and General Manager (VPGM) of ITW Welding Greater China, stated: “By leveraging ITW’s global R&D platform and manufacturing strengths, we have broken through traditional technological constraints, explored new pathways, and developed differentiated innovative products.”

This journey – driven by the precision of ITW’s 80/20 Front-to-Back Process, entrepreneurial culture, and seamless collaboration – stands as a testament to ITW's commitment to innovation.

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