Furnace-brazed fuel rail production at scale

Furnace-brazed fuel rail production at scale

29th October 2025 | 2 min read

The Challenge

A leading global engine manufacturer required a reliable, high-volume supplier for safety-critical fuel rail components. The production process demanded exceptional precision, tight tolerances and adherence to strict cleanliness standards. With limited suppliers globally able to meet these specifications – and no other UK-based production capability – the challenge was to deliver consistent quality at scale whilst meeting demanding timelines and optimising costs.

The Solution

Unipart invested in a dedicated fuel rail production facility in Coventry, installing a gas-powered hydrogen atmosphere brazing oven with precise temperature controls for up to 1,100°C brazing.

The process has been significantly upgraded with the furnace loading now fully automated for consistency, repeatability, and efficiency. The process offers:

  • High-volume capability – configured for up to 10,000 fuel rails per week, with flexibility for lower-volume, bespoke assemblies.
  • Safety-critical controls & total traceability – automated traceability and machine integration are installed on each process station with bar code scanning, and all transactions are recorded on a central database, creating a unique digital “product passport” with full traceability from raw material to final inspection. The traceability and interlocking system has been verified by a leading Tier 1 supplier as the global benchmark, giving customers confidence in the integrity of every product supplied.
  • Material versatility – capability to handle stainless steel, mild steel, brass, titanium and copper with precision.
  • Cost optimisation – continuous process improvements and supply chain efficiencies to deliver competitive value; as an example, a successful energy efficiency project on our furnace has delivered 60 tonnes of CO2 saving per year along with significant cost savings, whilst being aligned with Unipart’s energy monitoring and control system Energy Insight.

The Impact

Unipart’s approach is built on a culture of manufacturing excellence, lean thinking, and continuous improvement, ensuring processes never stand still. Every investment, from automation to advanced traceability, is made to deliver greater efficiency, consistency and value for customers.

The furnace brazing facility has delivered sustained, high-quality production over more than a decade, achieving consistently excellent delivery performance and zero critical quality concerns. The customer extended its contract – which included exporting fuel rails competitively to China – in recognition of Unipart’s quality, reliability and engineering partnership.

This proven and competitive capability is now available for sectors beyond automotive, including aerospace, defence, rail, HVAC and energy systems, offering:

  • Scalable UK-based manufacturing to reduce supply chain risk
  • Proven expertise in safety-critical applications
  • Flexible capacity for both high- and low-volume production

This mindset of refining processes and embracing innovation ensures that Unipart’s manufacturing capability will continue to evolve, meeting the future needs of customers across multiple sectors.

If you’re exploring brazing for high-integrity components, Unipart’s manufacturing expertise and track record could be the key to achieving your quality, scale and delivery goals.