When purchasing a welding machine, the biggest mistake most buyers make is focusing only on the initial price tag. The true measure of value lies in how much a machine saves—and earns—over time. APS Welding, based in Valsad, Gujarat, delivers high-performance machines across the globe. Through a recent collaboration with Relax Technofab, the data clearly showed how an efficient welding machine can pay for itself in under 6 months.
1. Why ROI Matters in Welding Machine Investment
Return on Investment (ROI) isn’t just about recouping costs—it’s about improving productivity, saving on consumables, reducing power bills, and minimizing downtime. APS machines like the Genesis STAR 400 were engineered with this philosophy, resulting in:
- Up to ₹39.87 lakh in annual savings
- Full machine cost recovery in less than 6 months
2. How to Calculate Welding Machine ROI
Here’s a simple formula:
ROI (%) = (Annual Savings – Equipment Cost) / Equipment Cost × 100
Example from Relax Technofab:
- Total savings per year: ₹39,87,573
- Cost of 32 APS Genesis STAR 400 machines: ₹15,95,200
- ROI = (₹39,87,573 – ₹15,95,200) / ₹15,95,200 × 100 = ~150%+ in just the first year!
- Power Savings: A Major ROI Factor
Genesis STAR 400 features superior inverter technology leading to:
- Lower kWh consumption per weld
- Better adaptability to voltage fluctuations
- Annual power savings: ₹15,57,440
Power-efficient machines mean fewer operational costs over time.
4. Consumables Savings: Reduce Waste, Save More
Relax Technofab’s switch to APS machines showed:
- Less spatter and better arc control
- Stable current despite arc length fluctuations
These benefits reduced filler and electrode waste, saving: ₹2,49,600 annually.
- Labor Cost Reduction: Do More with Less
Weld By Aps
Time is money. APS machines enable:
- Cleaner welds = Less grinding
- More arc time = Faster production
- Fewer weld repairs = Lower rework
Labor savings per year: ₹21,80,533
6. Factors to Consider Before Buying a Welding Machine
When evaluating machines, consider these critical ROI-impacting points:
| Factor | Why It Matters |
| Power Efficiency | Reduces electricity bills significantly |
| Weld Quality | Fewer repairs, less grinding, more customer satisfaction |
| Durability | Lower maintenance costs, longer lifespan |
| Arc Control | Supports complex joints and stable output |
| Portability | Adapts to field jobs and saves handling costs |
| Digital Monitoring | Easy procedure adherence with visible voltage/current |
| After-Sales Support | Ensures uptime with quick service and training |
7. Long-Term Value Beyond ROI
APS Welding machines provide:
- Weather-resistant builds (IP23 rated)
- Hot Start for E7018 electrodes
- Arc Force Control for uneven joints
- Multi-process upgradeability (future migration to MIG/MAG, SAW)
These features don’t just save money—they future-proof your investment.
Real-World Success Story: Relax Technofab
With 32 welding stations, Relax Technofab achieved:
| Cost Category | Annual Saving (₹) |
| Power | ₹15,57,440 |
| Labor | ₹21,80,533 |
| Consumables | ₹2,49,600 |
| Total Saving | ₹39,87,573 |
| Equipment Cost | ₹15,95,200 |
Time to ROI = <6 Months
Future-Ready with APS Welding APS doesn’t just stop at ROI. With future phases including semi-automatic MIG/MAG systems and hard automation (SAW), their machines grow with your business, increasing process efficiency from 55–60% (SMAW) to 90%+ (GMAW).
Article published by Vishal Baliya
