How to Choose the Right Welding Machine for the Business

In a conversation with Industry Outlook, Miteshkumar Jain, Managing Partner of Nikoarc, talks about the way manufacturers are increasingly turning to automation, compatibility with multiple materials, and energy-saving solutions while considering backup support, longevity, and cost savings during welding machine operation.  With growing emphasis on cost-effectiveness, quality, and skill gap issues, Jain underscores that selecting an appropriate welding machine is key to ensuring long-term reliability, minimizing operational expenses, and remaining competitive in an evolving industrial environment.

How are businesses rethinking welding machine choices to keep up with changing production needs and trends?

The term welding has a wide range of applications such as welding of ferrous material, non-ferrous material, and non-metals. Welding plastics or fiber optics is also a form of welding. There are two basic parameters that a company considers before making a decision, first, whether the equipment meets the production requirements, and second, whether the equipment is capable of welding a material that the company intends to work with.

Manufacturers are looking towards automation. Automation is a bit expensive compared to the basic equipment, and hence, the process of automation in this country is not moving at that pace. However, automation gradually takes place. Due to the lack of skilled labor, companies seek to minimize dependency on manual labor. Hence, when purchasing welding machines every company is primarily looking for an automation attachment that will make welding and production easier by using non-skilled labor.

What are the key factors Indian SMEs consider bigger in price when choosing welding machines that must stand reliably in challenging shop floor conditions?

There are two crucial things one is backup and another one is the quality of the machine. Clients may have some feedback about the quality of the machine such as before deciding on the brand they would look into whether it is a reliable product or not. However, the most important thing is that they need backup because it is equipment and it will fail at any time. So the first and most important criteria a client or SME looks at is what kind of a backup you have around, and how soon you can respond to a problem that may arise in your equipment.

How much do after-sales support, services, response time, and brand trust weight in Indian businesses invest in welding equipment for the long term?

A brand does matter; however, after-sales support and service support are the most essential parts of welding machines. The customer has to necessarily ascertain from the seller that backup will be provided, backup will be easily available, and the response time will be kept to the barest minimum.

How do you see the future welding equipment becoming more intuitive, connected, and aligned with the needs of next-gen Indian manufacturers?

There are new kinds of welding machines are emerging as far as metals are concerned. Lasers are the new technology that is easier and simpler to handle and just needs less skillful labor. Automating them is also easier, but the expense is a little more, however, this is gaining attention now.  A single laser welding machine can replace three ordinary welding machines. Similarly, three skilled laborers can be replaced by one single unskilled worker. This is going to take form slowly, and the development towards automation become easier, though high-tech machines will represent the future of welding machines.

How critical is multi-material compatibility in choosing the right welding machine today?

The term ‘multi-material’ remains ambiguous. However a ferrous and non-ferrous material comes under same category. Accordingly, welding machines are different kinds within the range. For example, when attempting to weld copper to Mild Steel, specialized machines are required to do those jobs. In that scenario Integration is crucial.

There is a demand for machines which can do all these kind of requirements. Such machines coming gradually with laser- based technologies. And that’s a crucial factor because there is a growing preference for machines which are capable to handle many requirements as possible.

How do businesses weigh initial investment against operational savings when choosing a welding machine?

There is a growing awareness about the operating cost of machines. That's why we are selling laser machines today. For example, an ordinary CO2 welding machine or MIG welding machine is available at a price of approximately Rs 50,000. In contrast laser machine costs around Rs 4,00,000. However, after purchasing the machine, the amount of savings will be realized in terms of production cost, electricity cost, post-welding cleaning jobs, and employing non-skilled labor. Investing in cheaper machines will cause extra expenses. Conversely, investing in a higher-cost laser machine will cut down the overall operating cost of the machine.

How are eco-friendly goals influencing the choice of welding equipment today?

Welding is not yet fully eco-friendly. Many manufacturers are trying to design welding machines that cost less and use less energy. However, it is hard to go green because those machines will generate some kind of pollution while manufacturing the machines or operating the machines. So as of now going fully green is difficult in welding.

How do regional conditions like heat, dust, or humidity affect welding machine selection?

Weather conditions can affect the welding machine selection. If a customer is in a humid environment, they will have their own experiences and concerns. When purchasing a machine they will ask questions such as whether the machine can tolerate humidity and what impact it might have. The climatic and operational conditions are the factors buyers take into consideration. For example, regions like Rajasthan, where the temperature ranges from 38 to 45 degrees, buyers will ensure the machine they are purchasing is capable of operating effectively under such extreme weather conditions.

How important is real-time data tracking in modern welding machines for process optimization?

Real-time data tracking is gradually growing. We are getting machines where we will be able to connect directly to data-receiving systems which will eventually help us understand how efficiently the machines can be put to use. However, this capability is most effective in highly automated processes where the human interface is minimal. In India, some companies already adopted such systems and it will take some time to grow and reach all levels of manufacturing.

How are policy shifts influencing the scale and type of welding machines businesses are investing in?

Policy shifts and infrastructure growth don't influence the type of welding machines. The only influence that leads companies to manufacture products in India is the incentives that come from the government. The welding manufacturing industry in India has been well-established for many years. We have started importing in a big way from China and some other places. With the new thrust by the government, there are a lot of manufacturers getting back to manufacturing in India.

How are semi-automated welding machines helping bridge the skill gap in India’s regional industries?

Semi-automated welding machines will help to bridge the skill gap. The cost factor is the only hindrance. A small workshop owner, who has to be dependent on a skilled welder, would prefer to buy equipment where he doesn’t have to supervision. With this equipment, he can have a less skilled worker who can operate the machine. However, the cost between an ordinary machine which requires skilled labor and an automated machine is too significant. As a result, automation is not yet going to the lowest levels of industry. Gradually, these equipment costs will come down and this will take over.