Haifeng Automation Overall Solution for Shoe Insoles
Industry Pain Points
01
Dual Deficiencies in Wearing Comfort and Durability
Traditional insoles feature uneven density and rapid elasticity attenuation, leading to poor cushioning and shock absorption effects. Prolonged standing or walking easily causes foot fatigue and soreness; meanwhile, common foaming or bonding processes are prone to deformation, collapse and delamination, resulting in a short service life and the need for frequent replacement.
02
Dual Hidden Risks in Environmental Protection and Health
Solvent-based production processes emit excessive VOCs with harmful residues remaining on insoles. In addition, the lack of antibacterial and breathable design leads to easy bacterial growth and peculiar smell after long-term use, endangering foot health.
03
Low Adaptability and Single Function
Manual cutting results in low precision, causing poor fit with the shoe cavity and easy slipping during wear. The functions are limited to basic cushioning, failing to meet personalized and scenario-based demands such as antibacterial protection, breathability and perspiration, and arch support.
Core of the Solution
With years of profound experience in polyurethane equipment manufacturing, Haifeng Automation focuses on “ultimate comfort, long-lasting durability, green health, and precise adaptation.” Leveraging independently developed core equipment such as automatic disc polyurethane casting machines and precision metering systems, combined with exclusive solvent-free/water-based PU processes, we have created a full-process solution covering material R&D, molding production, and quality inspection. Through the patented design of multi-mold continuous production, the insoles achieve the core goals of “strong cushioning, long-lasting elasticity, environmental safety, full functionality, and snug fit without slipping.” Suitable for various shoe types including casual shoes, sports shoes, work shoes, and business shoes, we provide one-stop services integrating “technical scheme design + core equipment supply + national on-site operation and maintenance.”
Core Solution Modules
R&D of High-Performance and Environmentally Friendly Materials
Custom elastic formula: Specifically developed solvent-free/water-based PU foaming formulas, with density (0.3-0.5g/cm³) and rebound rate (≥60%) adjusted according to the usage scenarios of different shoe types such as casual shoes, sports shoes, and work shoes. It delivers excellent cushioning and shock absorption, long-lasting elasticity, near-zero VOC emissions, and no harmful residues.
Integrated multifunctions: Antibacterial agents, breathable fillers, and special arch support components are added to the formula, achieving an antibacterial rate of ≥99% and air permeability of ≥500mm/s. It reduces foot pressure and eliminates odors effectively.
Material stability optimization: Passed aging tests and compression set tests, ensuring no collapse or deformation during long-term use, with a compression set rate of ≤8%.
Automated Precision Molding Production
Full-process automated production line
Equipped with Haifeng's independently developed automatic disc polyurethane casting machine (supported by patented multi-mold continuous production technology), featuring a metering and proportioning accuracy of ≤±1%. The entire production process is automatically connected, improving production efficiency, ensuring consistent product quality, and reducing raw material waste.
Custom mold and size adaptation
、Exclusive molds are manufactured based on the shoe cavity data of different shoe types such as casual shoes and work shoes, achieving a precision of ≤±0.5mm in one-time molding for a snug fit with shoe cavities without slipping. Customization of U-shaped textures, different thicknesses, and functional zones is also available to meet customers' diverse needs.
Modular function upgrade
To add functions such as anti-slip and arch support, only mold and process adjustments are required, enabling rapid iteration to adapt to different usage scenarios.
Comprehensive Quality Verification and Compliance Assurance
Core performance testing
Key indicators including cushioning, rebound, and wear resistance are tested to ensure a rebound rate of ≥60% and wear resistance of ≥30,000 cycles, with consistent performance meeting standards.
Intelligent quality inspection and sorting
Adopting visual inspection combined with automatic sorting, it can accurately identify surface defects and dimensional deviations, automatically removing unqualified products. With a testing efficiency of ≥80 pieces per minute, it achieves both high accuracy and efficiency.
Environmental and health testing
Complies with standards such as GB 18401 and EU REACH, with near-zero VOC emissions and an antibacterial rate of ≥99%. It fully guarantees foot health and production compliance from production to finished products.
Solution Value and Effects
| Dimension | Traditional Process | Haifeng Automation Solution | Improvement Effects |
|---|---|---|---|
| Cushioning Rebound Rate | ≤40% | ≥60% | Effectively distributes plantar pressure and significantly relieves foot fatigue |
| Defect Rate | 8-12% | 1-2% | Reduced by over 80%, minimizing rework losses |
| Raw Material Waste Rate | ≥12% | ≤4% | Reduced by 67%, saving over 150,000 RMB in raw material costs annually |
| Labor Requirement | 5000 people/line | 1-2 people/line | Reduced by over 80%, lowering labor costs and operational error risks |
| VOC Emissions | Excessive | Near zero | Meets environmental compliance requirements and breaks market access barriers |
| Antibacterial Rate | None | ≥99% | Inhibits bacterial growth and eliminates odors |
| Service Life | 1-3 months | 6-12 months | Extended by 2-4 times, enhancing product market competitiveness |
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.
