Use Case Study: Transforming Efficiency and Cost Savings for a Load Bank Manufacturer
A U.S.-based load bank manufacturer slashed costs by more than $400,000 annually after switching to Caster Connection, gaining tailored solutions at a 52% price reduction. When tasked with providing casters for 3,500-lb liquid-cooled load banks, Caster Connection delivered durable, cost-effective solutions built for extreme weight and environmental challenges.
Client Overview
A referral introduced Caster Connection to a U.S.-based manufacturer of load banks, a niche industry with only 5–6 similar companies in the market. The customer’s previous supplier had provided overpriced casters with limited customization options.
Initial Product
The manufacturer initially required 5”x1.5” casters with brakes, an uncommon size.
Pain Point
Overpriced casters significantly inflated operational costs, with little room for tailored solutions.
Solution
Caster Connection provided an identical product at a 52% price reduction, saving the customer approximately $500,000 annually. The customer now plans to purchase 50,000 casters annually at the new cost.
New Product Development
Recognizing Caster Connection’s ability to deliver high-quality, cost-effective solutions, the customer approached the team for assistance with a new product: liquid-cooled load banks.
Product Overview
- Used for testing generators and power sources in industries like healthcare and rental services (e.g., Sunbelt).
- Allows grid testing without shutdown, critical for facilities requiring uninterrupted power, such as hospitals.
- Weight: 3,500 lbs. per unit, necessitating robust mobility solutions.
Challenges
- The unit must withstand environmental elements, including potential water leaks.
- Requires manual mobility due to its size and weight.
Caster Connection's Solution
- Recommended 6”x3” cast nylon swivel casters and matching rigid casters for durability and mobility.
- Added heavy-duty Jtec floor locks to ensure stability during use.
- Eliminated brakes based on user preference for ease of operation.
Projected Impact
Annual production of 2,000 units, requiring four casters and one floor lock per unit.
Strategic Impact
Transitioning from the previous caster supplier to Caster Connection provided the manufacturer with a competitive edge and operational efficiency.
Cost Savings
- For their current caster needs, the customer would have spent $854,500 annually with their previous supplier.
- Caster Connection’s pricing of $407,875 represents a 52.2% reduction, saving over $400,000 annually.
Rapid Turnaround
- Product samples were approved and purchased within 90 days of engagement.
- Full-scale OEM production achieved in under six months, including tooling and sample approvals.
Functional Improvements
Switched to aluminum pedals for enhanced durability and user experience in the customer’s legacy products.
Customer Service Highlights
Caster Connection’s team demonstrated exceptional responsiveness and expertise throughout the process:
Accurate Specifications
The experienced sales team identified and delivered optimal caster and floor lock solutions on the first attempt.
Rapid Prototyping
Four prototypes were quickly produced and showcased at global trade shows, receiving excellent feedback.
Seamless Vendor Integration
Transition from the previous supplier to Caster Connection was achieved with minimal disruption, ensuring consistent production.
Conclusion
Caster Connection’s ability to deliver cost-effective, high-quality solutions significantly transformed the operational efficiency of this load bank manufacturer. By addressing both legacy and new product challenges, the team achieved unparalleled customer satisfaction, substantial cost savings, and robust growth opportunities. This success highlights the value of collaboration, innovation, and expertise in solving complex industry challenges.
Want to learn more about how better casters can improve your OEM products? Contact us to speak with a Caster Solutions Expert.
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