Haifeng Automation Overall Solution for Shoe Soles
Industry Pain Points
Insufficient Core Performance and Quality Stability
The wear resistance, slip resistance, impact resistance and other core performance of traditional shoe soles are weak, failing to meet safety requirements under complex road conditions. Meanwhile, reliance on manual proportioning and inadequate process control lead to significant performance variations among products of the same batch and a high defect rate.
Intense Pressure on Environmental Compliance
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.
Imbalanced Production Efficiency and Costs
Fragmented production links and high labor dependence not only cause over 15% of raw material waste, but also limit production capacity release, resulting in difficulty optimizing efficiency and costs.
Core of the Solution
With years of experience in polyurethane equipment manufacturing, Haifeng Automation centers on “robust performance, stable quality, green compliance, and efficient mass production”. Leveraging independently developed core equipment such as automatic disc polyurethane casting machines and single/double-density molding systems, we have created a full-process solution covering material R&D, automated molding, and quality verification. This solution achieves the core goals of “wear resistance, slip resistance, environmental friendliness, and high efficiency” for shoe soles, adapts to the needs of various shoe types, and provides integrated “technology + equipment + operation and maintenance” services.
Core Solution Modules
R&D of High-Performance and Environmentally Friendly Materials
Scenario-specific formula customization: Relying on Haifeng’s polyurethane R&D capabilities, we develop customized solvent-free/water-based PU formulas, adding functional ingredients based on shoe type requirements. We precisely adjust hardness (Shore A 55-85) and tear strength (≥30N/mm) to meet core performance standards.
Material performance optimization: Formula compatibility is verified through Haifeng’s test platform to ensure stable wear resistance, slip resistance, and other properties. With mold optimization experience, we avoid defects such as bubbles and uneven density.
Automated Precision Molding Production
Full-process intelligent production line
Equipped with Haifeng’s automatic disc polyurethane casting machine (supporting multi-mold cycle operation), it features precise metering (≤±0.8% accuracy), high-pressure foaming (18-22MPa), real-time monitoring of key parameters, and full-process automation.
Customized mold and process adaptation
Supports single/double-density molding, provides customized molds, and quickly responds to personalized needs.
Existing equipment upgrading and transformation
Install Haifeng’s intelligent modules to realize the transition from solvent-based to solvent-free processes, reducing costs and improving efficiency.
Comprehensive Quality Verification and Compliance Assurance
Core performance testing
Professional equipment is used to test wear resistance, slip resistance, and other indicators to meet industry standards.
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
Leveraging Haifeng’s overseas service experience, we assist in completing certifications to break through barriers to European and American markets.
Solution Value and Effects
| Dimension | Traditional Process | Haifeng Automation Solution | Improvement Effects |
|---|---|---|---|
| Core Performance Compliance Rate | Below 80% | Above 99% | 99%+ compliance rate; significantly improved safety supported by equipment stability |
| Defect Rate | 12-18% | Within 2% | Reduced by over 90%, minimizing rework costs |
| Raw Material Waste Rate | ≥15% | ≤5% | Reduce by 67%, saving over 250,000 RMB in raw material costs per line annually |
| Daily Output | 5000 pairs | 15000 pairs | Increased by 200%, enabling acceptance of large-scale orders |
| VOC Emissions | Excessive | Near zero | Achieve environmental compliance and obtain international certifications |
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.
