Breaking the Cost–Durability Deadlock｜How UJEN Zinc Alloy Handles Upgraded Powder Processing Equipment

This case describes how UJEN helped a leading Taiwanese powder and bulk material processing equipment manufacturer move beyond a cost-versus-durability dilemma in industrial handles. By switching from fragile zinc alloy handles and expensive iron handles to UJEN’s high-performance zinc alloy industrial handle, the client achieved both improved reliability and lower overall component cost, strengthening its competitiveness in global markets.

Client Background｜A Hidden Champion in Global Powder Processing Technology

The client is a Taiwan-based leader in powder and granule processing equipment, offering solutions that range from compact laboratory mills to large-scale production systems, as well as specialized machines for biotech and pharmaceutical R&D. With nearly ten patented technologies, including ultra-fine mills for pearl powder, oil-content mills for nuts and seeds, and high-speed horizontal mills for sugar, salt, and chemical raw materials, the company has earned strong trust from customers worldwide.

Its equipment is sold to markets including the United States, Japan, Canada, France, Australia, and multiple Southeast Asian countries, serving industries such as biotechnology, food, chemicals, pharmaceuticals, and cosmetics where precision and stability are critical.

Challenge｜Balancing Handle Durability and Cost in Industrial Equipment

On powder processing equipment, the operating handle is a high-touch component used for adjustments, access, and maintenance. Its durability directly affects equipment reliability and user experience. The client experienced two major stages of difficulty:

• Early-stage issue: handles made from zinc alloy supplied by another vendor were prone to breakage in real-world use, causing disruption, maintenance workload, and potential customer complaints.
• Reactive solution: to eliminate breakage, the client switched to iron handles, which offered better strength but significantly increased component cost and weakened the cost structure of the machines.

The result was a persistent trade-off: choosing durability meant sacrificing cost, and choosing lower cost meant risking performance issues. The client needed a solution that could satisfy both.

Turning Point｜Discovering the Potential of High-Performance Zinc Alloy with UJEN

During ongoing supplier evaluations and market research, the client was introduced to UJEN Development. UJEN recommended its zinc alloy industrial handle and explained the differences in material formulation, structural design, and die-casting process compared with conventional zinc alloy components.

Although the client was initially cautious about returning to zinc alloy, UJEN’s engineering confidence and technical data convinced them to run thorough internal tests. The results were clear: UJEN’s zinc alloy handle passed all durability tests and delivered strength and toughness far superior to the previous zinc alloy handles, approaching or matching the performance of some iron handles.

Most importantly, this performance was achieved at a cost lower than the iron handles the client had been purchasing.

UJEN Solution｜Redefining Zinc Alloy Through Engineering and Process Control

UJEN’s industrial handle solution combined:

• Optimized zinc alloy formulation tailored for strength and toughness in industrial applications
• Precision mold design to control wall thickness, ribbing, and stress distribution
• Controlled die-casting and post-processing to minimize internal defects and enhance structural integrity
• Consistent quality management under ISO 9001 to ensure repeatable performance across batches

Instead of treating zinc alloy as a low-end material, UJEN approached it as an engineering platform where design, tooling, and process integration unlock true industrial-grade performance.

Results｜Upgrading Performance and Cost, Enabling a Full Handle Replacement

Based on convincing test results and clear cost advantages, the powder equipment manufacturer decided to fully switch from its iron handles to UJEN’s high-durability zinc alloy handles. The decision delivered multiple tangible benefits:

• Significant reduction in component purchasing cost without sacrificing durability
• Improved equipment reliability by eliminating handle breakage issues
• Fewer service interventions and reduced risk of customer complaints
• Stronger cost structure and competitive pricing in international markets
• Stabilized and optimized supply of key components through partnership with UJEN

UJEN Insight｜Good Materials Need Great Engineering to Unlock Full Value

Many people hold fixed assumptions about specific materials. UJEN believes that with the right design, precise tooling, disciplined process control, and refined material formulations, even commonly used zinc alloy can achieve surprisingly high industrial performance.

This case illustrates UJEN’s strengths in:

• Deep understanding of material science and its practical application to real-world loads
• Advanced mold design and die-casting expertise that transform material potential into reliable parts
• Providing cost-effective solutions that balance durability, performance, and price for global equipment makers

If your equipment is facing issues such as underperforming components or unsustainable part costs, UJEN can help you re-evaluate material and design choices with a total engineering perspective. With four decades of experience and a commitment to stability, precision, and durability, UJEN delivers industrial hardware solutions that unlock hidden value and break traditional trade-offs.