# Boxed controller product for HVAC-R equipment

> From a Nordic HVAC-R manufacturer’s validated prototype to a boxed, tested controller — molding, PCBA and final assembly coordinated through GANI-owned and GANI-managed qualified processes.

Page: https://ganiindustrial.com/cases/hvac-controller-boxed-product · Language: en

This is the controller that sits inside HVAC-R equipment and runs it: reading sensors, driving compressors, fans and valves, holding the setpoint and reporting state. The customer designed it and validated a prototype. What they did not have was a way to produce it.

GANI took it to a boxed product. The plastic housing is molded, the PCBA is produced and tested, final assembly brings them together, and the finished unit is functionally tested and packed — coordinated through GANI-owned and GANI-managed qualified processes rather than being brokered across unconnected suppliers.

What the customer buys is a finished product in a box, to their design and their brand, arriving to a schedule. Everything between their prototype and that box — the tooling, the process, the test, the yield — is our responsibility rather than theirs.

## Starting point

The manufacturer had a validated controller prototype but no route to production: enclosure tooling, PCBA sourcing, assembly and test were all open, and their team wanted one accountable partner instead of coordinating four vendors.

Working prototypes, schematics and a preliminary BOM existed; nothing was industrialized and no tooling had been cut.

## What we need from you

- Validated prototypes with schematics and firmware image
- Preliminary BOM and approved-vendor constraints
- Enclosure CAD and appearance requirements
- Three-year volume forecast by variant

## Our scope

- DFM review across board, enclosure and assembly
- Injection molding tooling through a GANI-managed qualified toolmaker
- PCBA coordination with a qualified partner, assembly and test at GANI
- Design and build of the end-of-line functional test fixture
- Final assembly, labelling and boxed packaging
- Golden sample process with the customer’s engineering team

## Outcome

- Golden sample approved after joint review
- Series deliveries running at roughly 8,000 units/year across variants
- Every unit serialized with a stored test record
- Engineering changes handled through an agreed ECO process


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GANI Industrial — engineering, manufacturing and lifecycle for European OEMs. Bursa, Türkiye.
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