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Company Background: Founded in 2019, this specialized manufacturer focuses on producing acoustic and furniture foam materials. Their facility spans over 40,000 square meters and is located in Foshan, China.
Challenge Faced: The client sought to fully automate their foam production line, from the initial foam formation process through to the cutting stage.
However, the main challenges included:
- Manual production processes that limited efficiency
- Space constraints due to structural pillars in the factory layout
- Need for both long and short foam production capabilities
- Requirements for precise cutting and immediate edge finishing
Solutions We Provided: We developed a comprehensive, customized foam production and processing solution that included several key components:
- SR-HCF Horizontal Continuous Foam Production Line
- Highly efficient continuous foam production requiring only one hour of daily operation
- Equipped with a 50-meter conveyor system to accommodate both short and long foam production
- Significantly improved production capacity while maintaining quality
- SR-SCC Foam Transport Clamp
- Automated handling system for transferring foam to curing and processing areas
- Reduced manual handling requirements and improved workplace safety
- SR-CL Curved Conveyor Line
- Custom-designed solution to address factory layout constraints
- Innovative curved design bypassing structural pillars
- Maximized existing space utilization without requiring costly facility expansion
- Enhanced material flow to storage and processing areas
- Dual SR-HT001 Rail-Mounted Horizontal Cutting Machines
- Capability to cut foam lengths up to 100 meters
- Simultaneous processing of both long and short foam sections
- High-precision cutting capabilities
- Integrated automatic edge-trimming functionality
- Eliminated additional processing steps by completing cutting and trimming in one operation
Results Achieved
- Full automation of the foam production process
- Optimized space utilization despite structural constraints
- Reduced labor costs through integrated processing
- Improved production efficiency with single-step cutting and trimming
- Enhanced product quality through precise, automated processing
- Ready-to-ship finished products without additional processing requirements
Impact on Manufacturing Capabilities
This comprehensive automation solution transformed the client’s manufacturing capabilities, positioning them for increased productivity and future growth in the foam manufacturing industry.
