KOKO’s factory was built from the ground-up to produce its highly specialised bioethanol cooker. The highly-capable manufacturing team tailored all the equipment, tools and fixtures used to meet the stringent design requirements of the cooker.  

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Large scale manufacturing processes were customized to ensure minimum cycle times

​Sheet metal stamping, where progressive and stage tools with autoloaders are used to achieve the high precision needed to manage an ethanol flame

Injection moulding, where engineering-grade plastics are custom-moulded to cater to ethanol distribution

Powder coating, where heat and ethanol-resistant custom powder is used before the cooker is cured in a camel-back oven

Ultrasonic welding, for leak-free shear joints in the custom-moulded part

Projection welding, with tight tolerance fixtures for accurate welding of structural load-bearing parts

Laser welding, for leak-free joints in the burner assembly where the ethanol fuel is held

At the heart of the factory is a state-of-the-art toolroom. This toolroom is capable of full-scale development as well as high-quality tool maintenance that can increase tool life and deliver sustained output. The toolroom also supports the design, development and upkeep of fixtures, jigs and gauges across the shop floor.