Haifeng Automation Wet Process Leather Integrated Solution
Болевые точки отрасли
01
Imbalanced Efficiency and Flexibility
The production line operates at a speed of only 8-12m/min, making large-scale mass production difficult. Meanwhile, product changeover is cumbersome—switching between different specifications takes 1-2 days, with a loss rate of ≥12%—resulting in weak market responsiveness.
02
Insufficient Environmental Compliance and Product Performance
Solvent-based production processes emit excessive VOCs, making it difficult to meet the environmental access requirements of European and American markets and severely restricting market expansion.
03
Insufficient Environmental Compliance and Product Performance
Traditional processes have a DMF recovery rate of ≤85% and are prone to excessive VOC emissions, exposing enterprises to environmental regulatory risks. Additionally, products have weak mechanical properties, with folding resistance ≤100,000 cycles, making them hard to adapt to high-end application scenarios.
Основа решения
As a veteran enterprise in the polyurethane automation equipment industry, Haifeng Automation focuses on four core demands: “stable quality, efficient production, green compliance, and flexible adaptation”. It integrates independently developed intelligent wet process production equipment, high-efficiency DMF recovery systems, and digital process control systems, incorporating core equipment and process solutions into the entire industrial chain of wet process leather. Leveraging decades of technical experience in R&D of wet process leather production lines and environmental protection equipment, the solution adapts to multi-scenario application needs and provides an integrated one-stop service of “technical solution + equipment implementation + on-site operation and maintenance”, with the equipment achieving a trouble-free operation time of over 6,000 hours.
Модули основного решения
R&D of High-Performance Film-Forming Material Systems
Customized Film-Forming Formulas: Relying on Haifeng’s PU Application R&D Center, specially develop high-compatibility polyurethane resin formulas for wet processes, adding composite functional additives to improve film compactness and toughness, fundamentally reducing defects such as pinholes and cracks.
Material Stability Testing: Verify additive compatibility through multi-component proportioning tests, with a proportioning accuracy of ≤±0.8%; optimize the coating and penetration trajectory of the slurry on the base fabric using flow simulation technology to ensure film uniformity and product consistency.
Full-Process Automated Production System
Integrated Production Line
Provide customized complete production lines covering the entire process from base fabric pretreatment, slurry coating, and coagulation film formation to intelligent finished product sorting. Core equipment adopts high-end configurations independently developed by Haifeng, ensuring a slurry coating uniformity of ≥99% 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 new product adaptation cycle; simultaneously support the upgrading and transformation of existing equipment, adding intelligent temperature control, precise proportioning, and automated conveying modules to realize the transformation of traditional processes to intelligent ones, reducing labor and raw material losses.
Efficient Mass Production Guarantee
Integrate fragmented processes to increase the production line speed to 20-25m/min, with an annual capacity of 1.2-1.5 million ㎡, significantly breaking through the efficiency bottleneck of traditional processes and meeting large-scale production needs.
Comprehensive Quality Verification and Compliance Assurance
Intelligent Quality Inspection
Equipped with independently developed integrated testing equipment by Haifeng, covering key performance tests such as film thickness, defect identification, and folding strength. The testing efficiency is ≥50㎡/minute, with automatic sorting of unqualified products.
Intelligent quality inspection and process control
Adopts visual inspection and automatic sorting, adjusts parameters in real time, and controls the defect rate within 2%.
Certification Support Services
Cooperate with authoritative testing institutions to assist in completing multi-standard certifications, providing complete technical parameters and sample support to help enterprises break through high-end market access barriers.
Значение и последствия решения
| Размер | Традиционный процесс | Haifeng Automation Solution | Эффект улучшения |
|---|---|---|---|
| Эффективность производства | 8-12m/min | 20-25m/min | Increased by 1.5 times, enhancing mass production capacity |
| Product Qualification Rate | ≤82% | ≥98% | Annual cost savings of 200,000-300,000 RMB, reducing rework losses |
| DMF Recovery Rate | ≤85% | ≥95% | Environmentally compliant, reducing regulatory risks |
| Changeover Cycle | 1-2 дня | ≤1 hour | Efficient changeover, adaptable to multi-category production |
| Folding Resistance | ≤100000 cycles | ≥200,000 cycles | Performance upgrade, expanding high-end application scenarios |
| Film Uniformity | No clear standard | 99% | Significantly improved product quality consistency |
| Выбросы летучих органических соединений | Prone to exceeding standards | 10mg/m | Complies with environmental policies, facilitating high-end market access |
Процесс реализации
Исследование спроса
Техническая команда проводит исследования на месте, чтобы разработать индивидуальные решения.
Разработка формул и процессов
Полная адаптация и проверка осуществимости на базе центра исследований и разработок.
Настройка/трансформация оборудования и ввод в эксплуатацию
Завод завершает производство, инженеры проводят монтаж и пусконаладочные работы на месте.
Мелкосерийное пробное производство
Техническая команда отслеживает и оптимизирует параметры.
Установка на месте и серийное производство
Внедрение производственной линии и запуск массового производства, обеспечение технического руководства.
Поддержка инспекции качества и сертификации
Помощь в заполнении заявок на тестирование и сертификацию.
Послепродажная эксплуатация и техническое обслуживание
Предоставление услуг по техническому обслуживанию и модернизации на базе национальной сервисной сети.
