전 세계 시장에서 산업용 장화, 안전화, 농업용 장화, 방수 신발에 대한 수요가 증가하고 있습니다. 이러한 제품은 건설, 광업, 식품 가공, 석유 및 가스, 농업, 도시 공학 등에서 사용됩니다. 방수 신발 시장 진출을 고려하거나 기존 생산량을 늘리려는 제조업체에게 전자동 레인부츠 생산 라인은 가장 경제적인 투자 솔루션 중 하나로 부상하고 있습니다.

구식 유인 레인부츠 생산에 비해 자동 PU 레인부츠 제조 시스템은 신발 간의 일관성이 향상되고 작업자에 대한 의존도가 낮으며 생산 주기가 짧고 고품질의 제품을 생산할 수 있습니다. 하지만 많은 구매자가 프로젝트를 시작하기 전에 궁금한 점이 있습니다:

• 완전 자동 레인부츠 생산 라인에 어떤 기계를 포함해야 할까요?
• 워크샵에는 얼마나 많은 공간이 필요하나요?
• 어떤 생산 능력을 기대할 수 있나요?
• 어떤 자료를 자동으로 처리할 수 있나요?
• 얼마나 많은 투자가 필요하나요?
• 좋은 PU 기계 공급업체를 찾으려면 어떻게 해야 하나요?

이 가이드는 실제 공장의 관점에서 완전 자동 레인부츠 생산 라인의 가장 중요한 측면을 다룹니다.

전자동 레인부츠 생산 라인이란 무엇인가요?

완전 자동 레인부츠 생산 라인은 사람의 개입을 최소화하면서 방수 부츠의 전체 제조 공정을 자동화하도록 설계된 통합 시스템입니다.

파트 빈에서 소싱부터 PU 사출, 성형, 탈성형, 냉각, 마감까지 모두 프로그래밍 가능한 시스템의 제어 하에 자동으로 이루어집니다.

모던 라인에서는 일반적으로 다음과 같은 품목을 생산합니다:

• PU 레인 부츠
• PU 안전 부츠
• PVC 레인 부츠
• 이중 밀도 안전 신발
• 방한 산업용 부츠
• 농업 및 광업용 신발 방수 장화

PU 부츠는 기존 PVC 제품보다 가볍고 편안하며 내구성이 뛰어나고 단열성이 훨씬 우수하기 때문에 고급 신발 생산에는 PU 기술이 선호됩니다.

완전 전자동 레인 부츠 라인의 주요 장비

전체 레인부츠 생산 라인은 이러한 기계로 구성됩니다:

PU 소재 공급 시스템

공급 시스템은 사출 장치에 폴리우레탄 원료를 적절히 저장, 가열, 여과 및 공급합니다. 재료 공급의 품질과 안정성은 발포의 품질과 최종 제품의 다양한 품질에 큰 영향을 미칩니다.

피딩 시스템에는 다음과 같은 기능이 있습니다:

• 자동 온도 제어
• 자료 순환
• 가스 제거
• 미터링 제어
• 압력 안정화

중앙 집중식 공급 시스템은 더 높은 효율성이 요구되는 대규모 공장에서 주로 사용됩니다.

PU 사출기

PU 사출기는 전체 생산 라인의 핵심입니다. 이 장비는 폴리올과 이소시아네이트 재료를 혼합하여 원하는 비율로 금형에 주입하는 데 사용됩니다.

다음과 같은 기능이 있습니다:

• 고압 믹싱 헤드
• 정확한 투약
• 서보 제어
• PLC 터치스크린 작동
• 자동 데이터 처리
• 화학물질 낭비 최소화

최신 PU 신발 기계는 단일 밀도 및 이중 밀도 신발 생산을 모두 처리할 수 있습니다.

로터리 몰딩 컨베이어 시스템

대부분의 전자동 레인부츠 제조 공장에서는 회전식 컨베이어 시스템을 선호합니다. 여기서 금형이 항상 회전하며 다양한 자동 사출, 경화, 냉각 및 탈형이 순차적으로 이루어집니다.

장점은 다음과 같습니다:

• 지속적인 생산
• 출력 효율성
• 수작업이 덜 필요함
• 생산 낭비 감소
• 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
• 금형
• Installation
• 운영자 교육
• 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.

결론

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.

자주 묻는 질문

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.