Haifeng Automation Empowers Polyurethane Gasket Manufacturing A Production Line Upgrade Case for a Slovak Factory
고객 배경
A professional manufacturer of polyurethane gaskets in Slovakia has long been troubled by four core issues: unstable product performance, poor batch consistency, non-compliance with EU environmental protection standards, and lack of production data traceability. Based on the customer’s demands for high-precision molding and EU-compliant production, Haifeng Automation provided an integrated upgrade solution, including equipment replacement, process optimization, intelligent control, and environmental adaptation.
The customer introduced 2 sets of Haifeng XJJF-3×50Z70A polyurethane foaming and pouring machines and completed a full production line upgrade within 3 months, transforming from traditional extensive production to intelligent and precise manufacturing. All products fully meet EU industrial certifications and customer factory audit requirements, and have successfully entered the high-end supporting supply chains of automotive parts and light rail transit.
프로젝트 개요
The customer is a local industrial seal manufacturer in Slovakia, with 12 years of experience in the R&D and production of polyurethane gaskets and shock-absorbing sealing blocks. Its products are mainly used in automotive parts, precision machinery, and light rail transit, and all products must strictly comply with EU sealing performance standards and low-VOC environmental requirements.
The company originally operated 2 sets of outdated low-pressure foaming machines, which had been in service for a long time. As European customers continued to raise requirements for product accuracy, durability, and compliance, the original production mode could no longer adapt to market development, and professional polyurethane automation equipment was urgently needed for technological upgrading.
핵심 고객 고충 사항
01
Unstable product performance
The raw material mixing uniformity of the old equipment was less than 80%, resulting in uneven cell distribution of the gaskets. The seal failure rate was 8%–11%, which could not meet the precision sealing requirements of European industrial customers.
02
Low efficiency and high costs
The equipment relied on manual parameter adjustment, on-site inspection, and manual recording, leading to long molding cycles and low yield rates. The raw material ratio error exceeded 3%, and the raw material waste rate was 14%–17%. The entire production line required 12 operators, resulting in high labor costs and management difficulties.
03
Failure to meet EU compliance requirements
The equipment did not have a production data collection and storage function, unable to provide production traceability records, making it difficult to pass EU industrial product quality audits and customer factory inspections. It was also incompatible with low-VOC and halogen-free environmentally friendly raw materials, missing access to high-end markets.
04
Insufficient temperature control stability
There was no closed-loop constant temperature control system. The temperature fluctuation during foaming and curing exceeded ±5℃, leading to obvious differences in hardness and elasticity of the same batch of products. The qualified rate of finished products was only 82%, resulting in high rework costs.
하이펑의 솔루션
01
Core equipment upgrade
The outdated foaming equipment was replaced with 2 sets of Haifeng XJJF-3×50Z70A polyurethane foaming and pouring machines, equipped with a high-speed mixing head of 8600 r/min and a high-precision servo metering system with ±0.5% error, to achieve uniform raw material mixing and precise ratio control.
02
Intelligent temperature control optimization
An intelligent closed-loop constant temperature control system was equipped, with temperature control error controlled within ±1℃, to stably manage the whole process of foaming and curing, eliminating performance differences of batch products.
03
EU-oriented compliance transformation
A full-process production data collection module was built to automatically record key parameters such as ratio, temperature, pressure, and flow, and generate traceability reports, fully meeting EU quality management and factory audit standards. The flow channel structure of the equipment was optimized to be perfectly compatible with low-VOC and halogen-free environmentally friendly polyurethane raw materials.
04
Full-cycle localized support
Bilingual technical support in English and German was provided. Professional engineers were arranged to conduct on-site equipment installation, commissioning, and operation training. A 1-year whole-machine warranty and 24-hour remote technical support were provided to ensure stable and efficient operation of overseas production lines.
프로젝트 실행의 핵심 성과
Significant improvement in product performance
The raw material mixing uniformity exceeded 99%, and the ratio error was controlled within 0.5%. The seal failure rate dropped from 11% to 2.8%, and the service life of the products more than doubled.
Leapfrog improvement in production efficiency and quality
The qualified rate of finished products rose from 82% to 96.2%, and the daily production capacity increased by 45%. The raw material waste rate dropped from 16% to 9%, saving 12%–15% of raw material costs per year.
Full compliance with EU standards
The complete data traceability system helped the company pass all EU compliance audits and customer factory inspections 100%. It can stably produce environmentally friendly gaskets and successfully entered the supporting supply chain of European high-end equipment manufacturers.
Greatly reduced operating costs
The number of operators of the entire production line was reduced from 12 to 5. Automation replaced a large number of manual inspection, ratio, and recording work, saving a lot of annual labor costs. The stable operation of the equipment reduced rework and maintenance expenses, with annual comprehensive production costs reduced by 16%–18%.
Comprehensively enhanced market competitiveness
The company successfully obtained long-term supporting orders from 3 European automotive and rail transit enterprises, with annual sales increased by 48%, becoming a benchmark manufacturer of high-end polyurethane gaskets in Slovakia.
