Haifeng Automation Water-Based Leather Integrated Solution
Schmerzpunkte der Industrie
01
Dual Pressures of Environmental Protection and Cost
Traditional fiber opening processes use liquid caustic soda/toluene, featuring high energy consumption and high emissions. They pose great difficulties in environmental treatment, leading to persistently high compliance and overall production costs.
02
Low Quality and Yield
Products have a hard hand feel, uneven fluffiness, weak elasticity and mechanical properties, failing to meet the strict quality requirements of the high-end market. Additionally, relying on manual adjustment of parameters often results in uneven coating, with a product qualification rate of only 83% and severe rework losses.
03
Insufficient Production Line Adaptability
The changeover cycle for products of different specifications is as long as 1-2 days, coupled with large-scale equipment investment, making it difficult to flexibly respond to the production needs of multiple product categories.
Kern der Lösung
With over 30 years of experience in the polyurethane field, Haifeng Automation has developed an integrated full-process solution of “material process optimization + intelligent production + on-site operation and maintenance” based on independently researched and developed intelligent water-based coating equipment and low-energy fiber opening technology. The solution is suitable for multiple application scenarios such as shoe materials, automotive interiors, and electronic packaging materials, providing one-stop support including “technical solution design + core equipment supply + on-site operation and maintenance services”. The equipment achieves a trouble-free operation time of over 6,000 hours. Focusing on four core demands—”green cost reduction, high-end adaptation, efficient mass production, and flexible changeover”—it has helped numerous customers achieve capacity upgrading and enhanced market competitiveness.
Kernlösungsmodule
Environmentally Friendly and Cost-Effective Material Process
Green Fiber Opening Technology: Replaces traditional liquid caustic soda/toluene processes with an environmentally friendly fiber opening process, reducing carbon emissions by 30% and keeping VOC emissions < 10mg/m³, fully complying with environmental policy requirements.
Cost Optimization and Adaptability: Equipment investment can be reduced by 20%-30%, while being compatible with low-cost base fabrics, reducing the total production cost throughout the entire chain from equipment investment to raw material selection.
Dual Improvement of High-End Quality and Efficient Mass Production
High-End Texture Upgrade
Products offer a soft and delicate hand feel with uniform and full fluffiness. Their sensory experience is comparable to high-end similar products, accurately meeting the aesthetic and tactile requirements of the high-end market.
Enhanced Mechanical Properties
Passes the -20℃ folding resistance test (≥200,000 cycles) with a tear strength of ≥32N/mm, featuring stable and reliable physical properties and significantly extended product service life.
Dual Advantages of Mass Production Efficiency and Yield
The production line operates at a speed of 16-20m/min with an annual capacity of 800,000-1,000,000㎡, far exceeding traditional processes in efficiency. Through intelligent control of core parameters, the product qualification rate is increased to ≥98%, greatly reducing rework losses and production costs.
Upgrade of Flexible Changeover Capability
Rapid Changeover Adaptation
The changeover cycle is shortened to ≤1.5 hours, significantly reducing production connection time and improving order response speed.
Multi-Category Compatibility Support
Enables quick switching between more than 25 texture styles, flexibly adapting to the production needs of multiple categories and differentiated products.
Efficient Undertaking of Small-Batch Production
Adapts to small-batch production scenarios, balancing production flexibility and cost control, and enhancing the ability to undertake market orders.
Lösungswert und Auswirkungen
| Dimension | Traditionelles Verfahren | Haifeng Automatisierungslösung | Verbesserungseffekte |
|---|---|---|---|
| Qualification Rate | ≤83% | ≥98% | Annual cost savings of 120,000-180,000 RMB, reducing rework losses |
| Produktionseffizienz | 10-14m/min | 16-20m/min | Efficiency increased by over 50%, significantly boosting capacity supply |
| Carbon Emissions | High energy consumption and high emissions | Reduced by 30% | Complies with dual carbon policies, reducing environmental compliance pressure |
| Zyklus der Umstellung | 1-2 Tage | ≤1.5 hours | Rapidly responds to market demand, enhancing order acceptance capacity |
| Application Scenarios | Mid-to-low-end shoe materials, luggage | Covers high-end automotive interiors, electronic packaging materials | Achieve environmental compliance and obtain international certification |
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.
