Haifeng Automation Polyurethane Bicycle Tire Total Solution
Industry Pain Points
01
Dual deficiencies in production efficiency and flexible adaptability
Relying on manual production, each tire takes 3-5 minutes to manufacture, making large-scale mass production difficult; meanwhile, the production changeover cycle for products of different specifications and patterns is as long as 2-3 days, with weak equipment adaptability, failing to flexibly respond to multi-specification order requirements.
02
Poor product quality and stability
Manual operations lead to uneven foaming density and poor elasticity of tires, with large fluctuations in core performance indicators. The product qualification rate is only 85%, resulting in serious rework losses and directly affecting brand reputation and market competitiveness.
03
Dual pressures of cost control and environmental compliance
The raw material loss rate of traditional processes is ≥12%, with severe material waste pushing up production costs; at the same time, process pollution emissions exceed standards, making environmental compliance difficult. Enterprises face risks of policy fines and production restrictions, and struggle to expand overseas markets.
Core of the Solution
With decades of experience in the polyurethane equipment field, Haifeng Automation focuses on the core demands of “efficient mass production, precise quality control, green cost reduction, and flexible adaptability”. Integrating independently developed intelligent mixing and foaming systems, integrated molding equipment, and customized formula systems, it has created an end-to-end solution covering “material R&D + intelligent production + quality inspection + on-site operation and maintenance”. Suitable for tire production needs in multiple scenarios such as commuter bikes and mountain bikes, it provides one-stop services of “technical scheme design + core equipment supply + national on-site operation and maintenance”. The equipment achieves over 6,000 hours of trouble-free operation, helping enterprises realize synchronous upgrades in production efficiency, product quality, and environmental compliance, and enhance core market competitiveness.
Core Solution Modules
R&D of Scenario-Specific Specialized Polyurethane Materials
Customized environmental protection formula system: Relying on Haifeng’s PU Application R&D Center, develop specialized polyurethane foaming formulas for the performance needs of tires in different scenarios such as commuting and mountain biking. Precisely adjust material elasticity, hardness, and wear resistance to balance riding comfort and durability; adopt environmentally friendly water foaming technology, fully complying with ROSH/REACH international standards, reducing pollution emissions from the source, and controlling the raw material loss rate at 5%-7% to achieve a win-win situation of environmental protection and cost reduction.
Precise guarantee of material stability: Verify raw material compatibility through multi-component batching tests, combined with independently developed high-precision metering equipment, to ensure uniform foaming density and effectively avoid product quality defects caused by fluctuations in material properties.
Full-Process Automated Production System
Full-process integrated production line
Provide customized complete production lines covering all links from raw material pretreatment, intelligent mixing, integrated molding to automatic sorting. Core equipment adopts independently developed high-precision configurations, achieving a material mixing uniformity of ≥98% and stable and reliable operation.
High-speed mass production and energy-saving optimization
Adopt a production mode combining single-mold single-cavity and multi-mold linkage. The production efficiency is 1.5-2 minutes per tire for single-mold single-cavity, and as low as 1 minute per tire for multi-mold linkage, with an annual output of 800,000-1.2 million tires. Moreover, energy consumption is reduced by 20% compared with traditional processes, balancing efficiency and energy saving.
Flexible adaptability and equipment upgrading
Relying on CAD modeling and rapid mold development capabilities, realize flexible switching of 12-29 inch multi-specification/pattern tires within ≤1.5 hours (≤1 hour for similar specifications in the same series), adapting to multi-order requirements; simultaneously provide modular upgrading services to help traditional production lines transform from manual/semi-automatic to full-process automatic, maximizing the utilization of existing assets.
Comprehensive Quality Control and Compliance Assurance
Intelligent quality inspection
Equipped with Haifeng's independently developed integrated testing equipment, covering the detection of core performance indicators such as foaming density, hardness, elasticity, and puncture resistance. With high detection efficiency, it can automatically sort unqualified products, ensuring a product qualification rate of ≥98%.
Real-time precise temperature control
Adopt an intelligent production control system to dynamically adjust foaming temperature in real time, with a temperature error of ≤±1℃, ensuring the consistency of tire performance and improving the high-end quality performance such as puncture resistance of products.
Compliance certification support
Cooperate with authoritative testing institutions to assist enterprises in completing international standard certifications such as ROSH/REACH, providing complete technical parameters and sample support to help enterprises break through overseas market access barriers.
Solution Value and Effects
| Dimension | Traditional Process | Haifeng Automation Solution | Improvement Effects |
|---|---|---|---|
| Production Efficiency | 3-5 minutes per tire | 1.5-2 minutes per tire (1 minute per tire for multi-mold linkage) | Efficiency increased by more than 2 times, with an annual output of 800,000-1.2 million tires, meeting the needs of large-scale mass production |
| Product Qualification Rate | ≤85% | ≥98% | Significantly improved qualification rate, saving 250,000-350,000 RMB in rework costs annually |
| Raw Material Loss Rate | ≥12% | 5%-7% | Significantly reduced loss rate, reducing raw material waste and improving product profit margin |
| Production Changeover Cycle | 2-3 days | ≤1.5 hours (≤1 hour for similar series) | Greatly improved changeover efficiency, quickly responding to multi-specification orders and enhancing market flexibility |
| Environmental Compliance | High pollution, difficult to meet standards | Compliant with ROSH/REACH standards, environmentally friendly and pollution-free | Avoid environmental policy risks and smoothly expand overseas markets |
| Energy Consumption Level | High energy consumption | Energy consumption reduced by 20% | Reduce energy costs and realize green low-carbon production |
| Labor Demand | Rely on manual labor, high demand | Full-process automation, sharply reduced labor demand | Reduce labor costs and operational error risks, improving production stability |
Implementation Process
Demand Research
Technical team conducts on-site investigations to formulate personalized solutions.
Formula and Process Design
Complete customization and feasibility verification relying on the R&D Center.
Equipment Customization/Transformation and Commissioning
Factory completes production, with engineers conducting on-site installation and commissioning.
Small-Batch Trial Production
Technical team tracks and optimizes parameters.
On-Site Installation and Mass Production
Implement the production line and start mass production, providing technical guidance.
Quality Inspection and Certification Support
Assist in completing testing and certification applications.
After-Sales Operation and Maintenance
Provide maintenance and upgrading services relying on the national service network.
