Polyurethane Banana Cord Equipment Solution
Schmerzpunkte der Industrie
01
High realism and visual quality
Color and Texture Control:
During the curing process, polyurethane may yellow due to improper temperature or catalyst ratios, or it may affect surface gloss, making it difficult to achieve the natural matte or glossy finish of a banana peel. Additionally, replicating the “sesame seeds” or specific textures that appear on bananas in the late stages of ripening poses a significant challenge for equipment and manufacturing processes.
Density uniformity:
Bananas have a distinctive curved shape. If the mixing head (MX) of the equipment produces an uneven mix or if the pouring trajectory is not properly controlled, this can easily result in products with inconsistent firmness, or cause material buildup or gaps at the junction between the stem and the fruit.
02
Non-standard Molds and Demolding Challenges
Concrete pouring in confined spaces:
Banana molds are typically long and curved, which limits the design of the gate. If the equipment cannot accurately meter small flow rates or if the injection pressure is unstable, the material flow may not penetrate deep into the mold smoothly, resulting in internal bubbles or incomplete filling of the product.
Design of the demolding mechanism:
Since bananas have a smooth surface with no grip points, even a slight deviation in the ejection mechanism design can easily damage the skin of hard or semi-hard PU products, or even cause them to break. The machine’s clamping frame structure must be integrated with complex core-pulling or rotary demolding mechanisms, which increases the difficulty of system integration.
03
Process Flow and Material Properties
Reaction rate control:
Polyurethane foam cures quickly; if the equipment lacks a temperature control system or has low mixing precision, a process issue may arise during the casting of long, narrow products where “the front section has already cured while the rear section has not yet been filled.”
Mold temperature dependence:
The appearance and texture of banana peels are highly dependent on the control of mold temperature. If the temperature control of the equipment’s mold temperature controller is uneven, it will not only affect the rate of chemical reactions but also cause flow marks or an orange peel effect on the product’s surface.
Kern der Lösung
Haifeng Automation, a veteran in the polyurethane automation equipment industry, focuses on the core demands of “comprehensive protection, long-lasting durability, green environmental protection, and intelligent efficiency”. It integrates independently accumulated solvent-free/water-based PU technology, precision manufacturing processes, and intelligent quality control systems, integrating core equipment and process solutions into the entire industrial chain of safety shoes. Leveraging technical experience in PU foaming equipment, precision metering systems, and other fields, it achieves four core goals, adapts to multi-scenario needs, and provides integrated “technical solution + equipment implementation” services.
Kernlösungsmodule
R&D of Scenario-Specific Specialized Materials
Ingredients and formulation：
A1, A2 (polyester polyol), B1, B2 (isocyanate), C1-C4 (color paste)
Proportion range of raw materials: 100:40-70
Raw material preheating temperature: 60–70°C (Note: An oven is required.)
Other ingredients: Demolding agent (function: prevents adhesion), pigment (function: for shoe sole coloring), (MC) dichloromethane (function: cleans the machine nozzle), (DOP) dioctyl phthalate (function: cleans the material tank).
Castability：
Maximum instantaneous flow rate: 30–70 g/s Measurement accuracy: ±0.5.
Number of workstations: 24
Heating method: Electric heating / Water heating (optional)
Production Process (Semi-Automated)
| Step No. | Detailed Description | Corresponding Diagram |
|---|---|---|
| 1 | Manually place the fixed shoe upper into the designated mold. |   |
| 2 | Manually spray mold release agent. |  |
| 3 | The pouring machine automatically pours polyurethane raw materials. |  |
| 4 | Automatically close the mold. |  |
| 5 | Heating and curing (Electric heating / Water heating) Electric heating: Install heating pipes or heating plates on the mold backing plate, and heat the mold through contact conduction. Water heating: Set up a water heating tank next to the equipment, and circulate hot water or hot oil into the internal channels of the mold through hoses to heat the mold itself. |  |
| 6 | Automatically open the mold. |  |
| 7 | Manually remove the product, then trim the shoes, conduct quality inspection and acceptance, and finally package. |  |
Equipment List and Unit Price
| Serial No. | Name | Quantity | Dimensions | Unit Price (USD) |
|---|---|---|---|---|
| 1 | Mold Release Agent Spray Gun | 1 Set | Approx. (Unit mm) 105×155 | |
| 2 | Polyurethane Pouring Machine (2A1B) | 1 Set | Approx. (Unit mm) 1500×1500×2700 | |
| 3 | Heating Device (Electric or Water Heating) | 1 Set | Approx. (Unit mm) 900×600×1100 | |
| 4 | 24-Station Carousel Line | 1 Set | Approx. (Unit mm) 8000×9000×2350mm | |
| 5 | Color Dosing Machine | 1 Set | Approx. (Unit mm) 1000×800×1100 | |
| Hilfsmittel | ||||
| 1 | Storage Tank | 1 Set | Approx. (Unit mm) 500×500×2000 | |
| Luftkompressor | 1 Set | Approx. (Unit mm) 1800×1000×2000 | ||
| 2 | Raw Material Oven | 1 Set | Approx. (Unit mm) 1700×1360×2050 | |
| 3 | Kühler | 1 Set | Approx. (Unit mm) | |
| EXW Total Price | ||||
| Transport: 1×40 HQ Container | ||||
Configure Directory Table of Contents
| Kategorie | Component Name | Model / Spec | Remarks |
|---|---|---|---|
| Pouring System | Metering System | Component A: 20cc High-precision metering pump | Motor is 1.3KW servo motor with planetary reducer |
| Component B: 20cc High-precision metering pump | |||
| Color Dosing System | 0.6cc High-precision metering pump | Drive motor is 0.75KW servo motor, 50L storage tank | |
| Gantry System | Left-right data movement | Movement motor is 1.3KW servo motor | |
| Up-down data movement | Movement motor is 1.0KW servo motor | ||
| Mixing Head System | Needle valve mixing head | With independent cooling system | |
| Temperature Control System | Hot water tank | ||
| Material tank temperature | Independently control material tank temperature | ||
| 2 HP Water Chiller | Mixing head cooling | ||
| Mixing Head Cleaning System | 20L cleaning tank | ||
| Machine Frame Assembly | Frame structure | ||
| Kontrollsystem | PLC & Modules | Brand: Shenzhen Inovance H3U series PLC & modules | |
| 10-inch Touch Screen | Brand: MCGS | ||
| Low Voltage Electricals | Brand: DELIXI | ||
| Sensors | Brand: Inovance | ||
| Mold Opening/Closing Machine | Pneumatic cylinder drive opening/closing mold | Cylinder stroke: determined by mold weight and required force Stroke: depends on mold opening angle and height, generally upper mold opening angle needs ≥90° | |
| Mold Release Spray Gun | Model: MRS-R/F, Brand: Taiwan Baoli, Nozzle size ±20 | Air pressure: 2.0Mpa, Weight: 320g | |
| 24-Station Polyurethane Carousel Line | Overall dimensions: Total length approx. 8 meters, Number of stations: 24 | ||
Technical parameters
mould
| General Information | Women's Shoe Mold | Men's Shoe Mold |
|---|---|---|
| Function: First select the mold for the product to be made (Unified Mold) Material: Aluminum Alloy, Cr12MoV Alloy Tool Steel | Length: Approx. 220-280mm Width: Approx. 80-95mm Thickness: Approx. 15-30mm  | Length: Approx. 250-350mm Width: Approx. 90-110mm Thickness: Approx. 40-60mm  |
Raw material drying oven
| Function: Raw material oven for preheating and drying of AB material. Model: XHG×3-2.5; Volume: 2.5 m³; Temperature range: 90°C; Temperature control mode: Automatic; Total power: 6.55 kW. |  |
Automatic opening and closing die mold
| Function: Automatic mold opening and closing Power (KW): 1 | |
Molding release agent gun
| Function: Apply release agent before mold casting. | |
gating system
| Function: The casting machine operates according to the selected formula. Maximum instantaneous flow rate: 70 g/s; rated voltage V: 380 V; measurement accuracy: ±0.5‰; number of power phases: 3; metering pump speed adjustment range (rotations per minute): 30–150; mixing head speed (rotations per minute): 8600 ±150; rated power frequency (Hz): 50 Hz; equipped with a servo motor and planetary reducer; electrical cabinet: electrical control system; barrel material: stainless steel; barrel capacity: 120–220 (customizable according to customer requirements). |  |
Polyurethane banana-shaped wire for 24 workstations
| Function: The mold station automatically opens or closes. |  |
cooling-water machine
| Function: Cooling power for the pouring head and mixing chamber kW: 1.91 kW |  |
air pump
| Functions: Cleaning and valve control provide power and cooling source pressure for the pneumatic system and nozzle cooling (requires continuous power supply). Power: 22 kW |  |
Production output and production efficiency
| Production Mode | The production cycle time for each station is approx. 8-18 seconds. Different mold cavities may result in different cycle times for each station. | |
|---|---|---|
| Single Density / Double Density | Single Density | Double Density |
| Average Cycle Time | Approx. 3-5 minutes | Approx. 5-10 minutes |
| Hourly Output | ≈ 144-240 pairs | ≈ 72-144 pairs |
| Daily Output (8 hours) | ≈ 1152-1920 pairs | ≈ 576-1152 pairs |
Working Conditions
| Artikel | Requirements |
|---|---|
| Workshop Requirements | Level ground (area approx. 8m×6m), power supply, compressed air, cooling water, ventilation |
| Temperature & Humidity | ≤40°C, non-condensing environment |
| Stromversorgung | 3×380V±5%, 50Hz, reliable grounding (provided according to actual site requirements) |
| Operators | 2-4 trained operators (including injection control, sampling, placing uppers, trimming, air blowing) |
Vollständig automatisiertes Produktionssystem
Integrated production line
Provide customized complete production lines covering all processes from raw material pretreatment to intelligent sorting. Core equipment adopts Haifeng's independently developed imported configuration, ensuring material mixing uniformity ≥98% and stable and reliable operation.
Customized adaptation
Rely on the CAD modeling and 3D printing capabilities of the Mechanical Design Research Institute to quickly produce customized molds and non-standard components, shortening the R&D cycle of new styles to 7-10 days.
Existing equipment transformation
Install Haifeng's intelligent temperature control, precision proportioning, and automated conveying modules to realize the transformation from solvent-based to solvent-free/water-based processes, reducing labor and raw material losses.
Umfassende Qualitätsüberprüfung und Konformitätssicherung
Intelligent quality inspection
Equip Haifeng's independently developed integrated testing equipment, covering thickness, defect, bonding strength, and key performance tests. With an efficiency of ≥50 pairs per minute, defective products are automatically sorted out.
Real-time control
Adopt Haifeng's intelligent production control system to dynamically adjust parameters, controlling the defect rate at 2-3%; integrate environmental monitoring modules to achieve near-zero VOC emissions.
Certification support
Cooperate with authoritative testing institutions to assist in completing multi-standard certifications, providing technical parameters and sample support to help obtain CE and LA certifications and break through high-end market barriers.
Lösungswert und Auswirkungen
| Dimension | Traditionelles Verfahren | Haifeng Automatisierungslösung | Verbesserungseffekte |
|---|---|---|---|
| Compliance Rate of Protective Performance | Below 85% | Above 99% | Meet national/international standards and eliminate safety hazards |
| Defect Rate | 10-15% | 2-3% | Reduce by over 75% and minimize rework losses |
| Raw Material Waste Rate | ≥15% | ≤5% | Reduce by 67%, saving over 300,000 yuan in raw material costs per line annually |
| Labor Requirement | 8-10 people/line | 2-3 people/line | Reduce by 75% and lower the risk of operational errors |
| VOC-Emissionen | Excessive | Nahe Null | Achieve environmental compliance and obtain international certifications |
| R&D Cycle | 30-45 days | 7-15 days | Shorten by over 60% for rapid market response |
Prozess der Umsetzung
Nachfragerforschung
Das technische Team führt Untersuchungen vor Ort durch, um personalisierte Lösungen zu erarbeiten.
Formel und Prozessgestaltung
Vollständige Anpassung und Überprüfung der Machbarkeit durch das F&E-Zentrum.
Geräteanpassung/Transformation und Inbetriebnahme
Das Werk schließt die Produktion ab, und die Ingenieure führen die Installation und Inbetriebnahme vor Ort durch.
Kleinserien-Versuchsproduktion
Das technische Team verfolgt und optimiert die Parameter.
Vor-Ort-Installation und Massenproduktion
Implementierung der Produktionslinie und Beginn der Massenproduktion unter technischer Anleitung.
Unterstützung bei Qualitätsinspektion und Zertifizierung
Hilfestellung beim Ausfüllen von Prüfungs- und Zertifizierungsanträgen.
Betrieb und Wartung nach dem Verkauf
Erbringung von Instandhaltungs- und Modernisierungsdiensten auf der Grundlage des nationalen Servicenetzes.
