Haifeng Automation Upgrades PU Solid Tire Production Line to Help Brazilian Enterprises Expand South American Construction Machinery Supporting Market
Customer Background
The enterprise is a local professional manufacturer of polyurethane solid tires in Brazil, with 21 years of experience in R&D and production of forklift tires, engineering vehicle solid tires and port heavy-duty tires. Its products have long been supplied to logistics, mining, port and engineering rental markets in South America.
With the rapid growth of the South American electric forklift and construction machinery market, local mainstream equipment manufacturers have put forward higher requirements for supporting tires in terms of load-bearing performance, wear resistance, dimensional consistency and quality stability. The enterprise’s original semi-automatic production line had obvious bottlenecks in molding uniformity, bonding reliability, production data traceability and multi-specification quick changeover, making it difficult to meet high-end supporting requirements.
Project Overview
Brazilian solid tire manufacturers have long faced problems such as insufficient tire internal density, unstable rim bonding, low efficiency in multi-specification production change and lack of production data traceability, resulting in insufficient competitiveness in the high-end supporting market.
Based on the application characteristics of polyurethane solid tires including high load-bearing, high wear resistance, free-inflation and long service life, Haifeng Automation customized three sets of special intelligent pouring production lines for polyurethane tires for the customer. The solution helps the customer realize intelligent production with stable molding, precise proportioning, constant temperature curing and data traceability, comprehensively improves product quality and batch delivery capacity, and successfully expands the supporting market for construction machinery and industrial vehicles in South America.
Core Customer Pain Points
01
Insufficient tire molding uniformity, easy to generate bubbles and density differences
Limited mixing and pouring accuracy of traditional equipment leads to uneven internal structure of tires, affecting load capacity, durability and long-term safety.
02
Unstable bonding strength between rim and polyurethane material
Manual processing and traditional processes are difficult to ensure bonding surface consistency, easily leading to insufficient local bonding and affecting product reliability.
03
Long changeover cycle for multi-specification tires, insufficient flexible production capacity
The enterprise’s products cover various models and specifications. The traditional production line is cumbersome in debugging and cannot quickly respond to the market demand for multi-variety and small-batch supporting.
04
No data recording in production process, imperfect quality traceability system
Parameter adjustment relies on manual experience without key process parameter records, making it difficult to provide stable and reliable quality certification to supporting customers.
05
Low raw material utilization rate and high cost in large-scale production
Old pouring equipment has high residual material and insufficient proportioning control accuracy, resulting in raw material waste and high cost pressure in fierce market competition.
Haifeng's Solutions
01
Special high-precision pouring system for tires to improve density and stability
Adopting special pouring equipment for polyurethane tires to achieve precise metering, uniform mixing and stable pouring, improve the internal structure uniformity of tires from the source, and enhance load-bearing and wear resistance.
02
Standardized pretreatment and constant temperature curing process to improve bonding reliability
Standardized bonding surface treatment and mold constant temperature control ensure stable combination of polyurethane and rim, and improve overall reliability and service life of products.
03
Intelligent multi-formula storage to realize rapid change of multi-specifications
The equipment supports the storage and one-key call of multiple sets of process parameters, reducing manual debugging time and improving flexible production efficiency of multi-specification products.
04
Whole-process process data monitoring to improve the quality traceability system
The system automatically collects key data such as temperature, proportion, flow and operating parameters to form complete production records, meeting the requirements of supporting customers for stable quality and process traceability.
05
Low-residue high-efficiency pouring structure to improve raw material utilization
Optimize flow channel and metering structure to reduce residual material and waste, reduce labor dependence with automatic operation, and effectively optimize comprehensive production cost.
06
Overseas on-site services ensure stable operation of production lines
Haifeng engineers go to the site to complete installation, commissioning, process optimization and personnel training, provide whole machine warranty and remote technical support to ensure long-term stable operation of the production line.
Core Achievements of Project Implementation
Significantly improved product quality and successfully entered the South American high-end supporting market
The tire’s density, uniformity, wear resistance and reliability have been comprehensively improved, recognized by local construction machinery and industrial vehicle manufacturers, and successfully expanded high-end supporting business.
Enhanced batch stability and significantly reduced product defect rate
Stable and controllable molding and bonding processes, significantly improved batch consistency, and greatly reduced customer complaints and rework rates.
Upgraded flexible production capacity and accelerated order response speed
Improved multi-specification rapid production change capacity, can efficiently undertake diversified orders, and significantly enhanced market response and delivery capacity.
Improved raw material utilization and continuously optimized production cost
The low-residue and high-precision operation mode effectively reduces raw material waste. Combined with the improvement of automation efficiency, the enterprise’s profitability is further enhanced.
Improved quality system and comprehensively enhanced market competitiveness
The complete production data and traceability system help the enterprise establish a more standardized quality management system and build a professional and reliable brand image in the regional supporting market.
