The global market is seeing increasing demand for industrial rain boots, safety boots, agricultural boots, and waterproof footwear. They are used in construction, mining, food processing, oil & gas, farming, municipal engineering, and more. For manufacturers considering entering the waterproof footwear market, or who seek to increase existing capacity, a fully automatic rain boot production line has emerged as one of the most economical solutions to invest in.

Compared with old-fashioned manned production of rain boots, automatic PU rain boot manufacturing systems offer better consistency between shoes, less reliance on workers, shorter production cycle times, and higher quality products. But many buyers have questions before launching a project:

• What machines to include in a fully automatic rain boot production line?
• How much space will the workshop need?
• What production capacity can be expected?
• What materials can be processed automatically?
• How much investment will be needed?
• How do I find a good PU machinery supplier?

This guide addresses the most important aspects of a fully automatic rain boot production line from a practical factory standpoint.

What Is a Fully Automatic Rain Boot Production Line?

A fully automatic rain boot production line is an integrated system designed to automate the entire manufacturing process of waterproof boots with minimal human interaction along the way.

Sourcing from part bins to PU injection, molding, demolding, cooling down, and finishing all happen automatically under the control of programmable systems.

With modern lines we usually produce the following items:

• PU rain boots
• PU safety boots
• PVC rain boots
• Dual-density safety footwear
• Cold-resistant industrial boots
• Footwear waterproof boots for agriculture and mining

PU technology is preferred for production of high-end footwear because PU boots are light, more comfortable, more durable and much better for insulation than old PVC products.

Main Machines in a Complete Fully Automatic Rain Boot Line

A complete rainboot production line consist of these machines:

PU Material Feeding System

The feeding system suitably stores, heats, filters and feeds the raw polyurethane materials in the injection unit. The quality and stability of the feeding of the material largely affect the quality of the foaming, and the various qualities of the endproducts.

The feeding system possesses the following features:

• Automatic temperature control
• Material circulation
• Degassing
• Metering control
• Pressure stabilization

The centralized feeding system is predominant in big factories who require greater efficiency.

PU Injection Machine

The PU injection machine is the heart of the complete production line. This equipment is used for the mixing of the polyol and the isocyanate materials and injecting them in desired proportions into the moulds.

It has the following features:

• High-pressure mixing head
• Precise dosing
• Servo control
• PLC touchscreen operation
• Automatic data handling
• Minimum wastage of the chemicals

Modern PU shoe machines can take care of production of both single density and double density footwear.

Rotary Molding Conveyor System

Most of the completely automatic rain boot manufacturing factories have a preferred rotary conveyor system. Here the moulds turn all the time and the various automatic injection, curing, cooling and demoulding takes place in sequence.

The advantages are:

• Continuous production
• Output efficiency
• Less manual labour required
• Lower wastage of production
• Stable cycle time
• Easier supervision for production management

The number of stations can be varying on requirement of the production capacity.

Mold Heating & Temperature Control Equipment

Mold temperature stability is also critical in PU footwear. Irregular temperatures will also lead to bubbles, shrinkage, and poor surfaces.

Automatic temperature control systems keep:

• Uniform density of the foam
• Better binding strength
• Stable dimensions of the boots
• Good appearance of the surfaces

Cooling and Demolding Equipment

After foaming and curing, the boots pass through cooling stations that remove them from the mold. Demolding may also be done automatically as a labor saving operation and to avoid deforming the product.

Some more advanced systems also have robotic boot removing device.

Finishing Equipment

• Flash trimming
• Edge cleaning
• Surface verification
• Logo printing
• Packing systems

Some factories depending on the degree of automation integrated into the rest of the production operations have either robotic trimming or automatic packing devices.

What is the Rain Boots Fully Automatic Making Process Like?

The flow of work is generally along these lines:

1. Raw materials preparation
2. Puller Rollers
3. Automatic Feeding
4. Mold Preheating
5. PU Injection
6. Foaming and Curing
7. Post Curing Cooling
8. Automatic demolding
9. Trimming and finishing
10. Quality Inspection
11. Packing of the boots

The entire process is controlled from an agglomerated central PLC which attempts to maintain stable conditions of operation in the production line.

Advantages of Going Full Automatic for Rain Boot Production

Greater Turnover

Fully automatic lines can run continuously and produce better timing output than the manual production process systems.

Many medium sized factories produce thousands of pairs of rain boots each day with the rotary PU system of forming and production.

Lower Manpower Requirements

There have historically been many worker/prize buyout operations required in some of the lines for this rain boot production due to the procedures for mixing, injection, demolding, trimming etc.

Automation makes pure manpower less noxious in its long term control.

Better Product Consistency

Automated dosing and injecting systems yield more consistent:

• Weight
• Foam density
• Surface finish
• Bonding quality
• Dimensional accuracy

Very important where PU rain boots are being exported.

Decreased Material Waste

Due to improved metering, the waste of polyurethane and other raw materials is reduced by more tightly controlled dispensing.

Easier Factory Scheduling and Management

Routine management of production scheduling and quality control, as well as the maintenance of the facility itself, is easier.

PU or PVC Rain Boot Making?

Often when buying rain boot making machinery, potential investors have to choose between the advantages of PU versus PVC.

PU Rain Boots

Pro

• Lighter
• More flexible
• More comfortable in general for prolonged use
• Offers better insulation from heat and cold
• Greater slip resistance
• Wear longer

Won widespread use in cold climates, interior & mining work and in many industrial safety applications.

PVC Rain Boots

Pro

• Less costly in general
• Easier to begin producing
• More suited to basic low-end market

However, harder on feet and heavier overall compared to PU footwear.

Space Requirements of a PU Rain Boot Factory

What is required in terms of space for a PU rain boot factory?

Space requirements will depend on the planned level of automation and thus, on the plant’s producing capability.

For a reasonable general idea in relation to a fully automatic rain boot factory we can expect:

A properly laid out factory of course should facilitate the carriage of material in the various stages of production and easy expansion in future. Care should be taken when laying down the blueprints to ensure such.

Investment of a Fully Automatic Rain Boot Production Line

The investment depends on the size of the plant, how automated it is, number of stations, number of moulds, type of material being produced, utilities required, use of robots, and even whether the factory has already been laid out.

A PU rain boot production project packaged as a turnkey solution may include:

• Machinery
• Moulds
• Installation
• Operator training
• Formula assistance
• Remote support in servicing
• Spare parts package

To get an accurate price quote, manufacturers typically devise a solution tailored to the buyer’s market segment and production intentions.

How to Select a PU Machinery Supplier

Selecting a supplier is one of the most important decisions that you will have to make in your polyurethane factory project.

Industry Experience

Look for a supplier with experience. He will have known:

• The chemistry
• How to troubleshoot production
• The design of moulds
• How to lay out a factory of useful size
• How to avoid waste with useful economy

Turnkey Project Capability

A good supplier will be able to:

• Design the lay-out of the factory
• Install the machines
• Give training in operation of machinery
• Assist with the formula
• Provide support in technical trouble-shooting after sales

Evaluate After-Sales Service

The PU machinery will require this regarding:

• Trouble-shooting remotely
• Supply of spare parts
• Mixing head maintenance
• Upgrading machines as operation advances
• Assistance in optimising the operation

Export Experience

More experience of electrical requirements for the various countries abroad.

Know how to organise the loading and transporting of containers for each shipment.

Have experience in installation abroad.

Have familiarity in these:

• Technical documentation
• Plastic foams technical services

Future Orientations in the Rain Boot Sector

This industry will centre around:

• Full automation
• Energy saving equipment
• Solvent-free methods
• Smart factory systems
• Robotic finishing systems
• Bio-based PU materials

Looking to the future and investing in automation today can help manufacturers respond better to labour shortages and rising quality requirements.

Conclusion

A fully automatic rain boot production line is no longer just the territory of large footwear companies. With increasing wages and higher quality demands, automation is becoming necessary for many factories.

Whether it is your first PU rain boot factory or a reconfiguration of your entire production process, the right factory layout, machinery configuration, and technology partner will be critical to your long term success.

A good PU rain boot production line can help manufacturers stabilize quality, reduce waste and improve efficiency, allowing them to move into higher margin industrial footwear markets.

FAQ

1: What is the best material for rain boot production?

There are many high quality boots made of PVC, EVA or PU. PU is often chosen for its lightweight comfort, durability, thermal insulation and long service life.

2: What is the production capacity of a fully automatic rain boot line?

Production capacity depends on machine configuration and choice of the number of stations. Large automatic rotary systems can produce several thousand pairs of boots per day.

3: Can I make multiple sizes of boot on a single production line?

Yes. The same line can produce different sizes and designs of boot simply by changing the mold.

4: Is training necessary for operators of PU rain boots?

Yes. Operators require training covering topics such as handling materials, operating machine type, managing molds, and quality control.

5: How long does it take to install a PU rain boot production line?

The installation time varies project by project. Most turnkey projects require several weeks, with time for installing the equipment, commissioning and training the operator teams.

6: What is the wastage and maintenance work required for PU shoe machines?

Keeping the mixing head clear, inspecting the hydraulic system, and checking the electrical system and the temperature calibrations of the workstation and sealing equipment are all requirements in the regular schedule of taking care of PU shoe machine production.

Also, the seals are usually replaced during this time, as is lubrication of multiple moving parts.