Haifeng Automation Dry Process Leather Integrated Solution
Industry Pain Points
01
Unstable Bonding Quality
Traditional production relies on manual temperature and pressure control, lacking precise process regulation methods. This easily leads to issues such as bubbles and warping, with a product qualification rate of only 85%, failing to meet stable quality requirements.h
02
Imbalanced Efficiency and Cost
Production processes are fragmented and disconnected, with a low level of automation, resulting in a production capacity of only 50-80㎡/hour. Additionally, it is only suitable for single-product production, with a changeover cycle as long as 1-2 days and a loss rate of ≥10%, leading to persistently high comprehensive production costs.
03
Insufficient Environmental Compliance and Durability
Traditional processes use solvent-based adhesives, resulting in excessive VOC emissions. Enterprises face the risk of environmental penalties and struggle to enter the high-end market. Meanwhile, products have poor durability, with dry rub fastness ≤Grade 3, leading to a high after-sales complaint rate.
Core of the Solution
As a seasoned 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 bonding technology, environmentally friendly adhesive systems, and digital production control systems, incorporating core equipment and process solutions into the entire industrial chain of dry process leather. Leveraging decades of technical experience in intelligent production lines and adhesive applications, the solution adapts to multiple scenarios such as shoe materials, luggage, and automotive interiors, providing an integrated one-stop service of “technical solution + equipment implementation + on-site operation and maintenance”. The equipment achieves a trouble-free operation time of over 6,000 hours.
Core Solution Modules
R&D of Environmentally Friendly and High-Performance Adhesive Materials Customized Adhesive Formulas
Customized Adhesive Formulas: Relying on Haifeng’s PU Application R&D Center, specially develop solvent-free adhesive formulas containing composite functional additives. Through independently developed high-precision metering equipment, precisely adjust material hardness and bonding strength to balance bonding stability and product durability.
Material Stability Testing: Verify additive compatibility through multi-component dosing tests, with a proportioning accuracy of ≤±0.8%; optimize the coating trajectory of adhesives on bonding surfaces using flow simulation technology to avoid bonding defects in key areas.
Full-Process Automated Production System
Integrated Production Line
Provide customized complete production lines covering the entire process from substrate pretreatment to intelligent finished product sorting. Core equipment adopts high-end configurations independently developed by Haifeng, ensuring an adhesive coating uniformity of ≥98% 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 transition from solvent-based to solvent-free processes, reducing labor and raw material losses.
Efficient Mass Production Guarantee
Integrate fragmented processes to achieve a production efficiency of 120-150㎡/hour and an annual capacity of 600,000-800,000㎡, significantly breaking through the efficiency bottleneck of traditional processes.
Comprehensive Quality Verification and Compliance Assurance
Intelligent Quality Inspection
Equipped with independently developed integrated testing equipment by Haifeng, covering key performance tests such as bonding thickness, defect identification, and bonding strength. The testing efficiency is ≥50㎡/minute, with automatic sorting of unqualified products.
Real-Time Process Control
Adopt Haifeng's intelligent production control system to dynamically adjust process parameters, controlling the product defect rate within 2%; integrate environmental monitoring modules to achieve near-zero VOC emissions
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.
Solution Value and Effects
| Dimension | Traditional Process | Haifeng Automation Solution | Improvement Effects |
|---|---|---|---|
| Core Performance | 50-80㎡/hour | 120-150㎡/hour | Increased by 1.5-2 times, meeting large-scale mass production needs |
| Product Qualification Rate | ≤85% | ≥98% | Significantly reduce rework losses and lower quality costs |
| Changeover Cycle | 1-2 days | ≤1.5 hours | Adapt to multi-category production and improve order response speed |
| Loss Rate | ≥10% | 7%-9% | Annual cost savings of 100,000-150,000 RMB |
| VOC Emissions | Excessive | Near zero | Achieve environmental compliance and obtain international certifications |
| Durability (Dry Rub Fastness) | ≤Grade 3 | ≥Grade 4 | After-sales complaint rate reduced by over 70% |
Implementation Process
Demand Research
Technical team conducts on-site investigations to formulate personalized solutions.
Formula and Process Design
Complete customization and feasibility verification relying on the R&D Center.
Equipment Customization/Transformation and Commissioning
Factory completes production, with engineers conducting on-site installation and commissioning.
Small-Batch Trial Production
Technical team tracks and optimizes parameters.
On-Site Installation and Mass Production
Implement the production line and start mass production, providing technical guidance.
Quality Inspection and Certification Support
Assist in completing testing and certification applications.
After-Sales Operation and Maintenance
Provide maintenance and upgrading services relying on the national service network.
