In principle, facility installed in a factory largely determines production efficiency and product quality. When initially designing our factory, we conducted a comprehensive investigation of equipment available, and selected a set of cutting-edge equipment based on critical criteria recommended by a panel of experts.
The whole production lines can simply be divided into two parts, namely, production lines manufacturing base, and downstream processing steps (such as laminating, printing, engraving, tumbling, and so on) which transform base products into final products according to our customers’ specifications.
Illustrated below are some equipment dedicated to serving our customers.
1. Calendaring lines
Our PVC Calendaring line comprises 4 heavy, gigantic and highly polished steel rolls. After the blend of PVC resin and additives (plasticizers, stabilizers, lubricants, pigments and processing aids) are extruded, the homogeneous melt passes through these rollers and are transformed into PVC leather sheets.
2. Wet processing lines/wet coagulation lines
Wet processing or coagulation process produces PU bases, which serve as foundation for further processing or treatment. Non-woven fabrics or knitted fabrics are usually used as backing fabric. The fabrics are cleaned, dipped in wet PU slurry, and passed between rollers so that coagulation can be accomplished.
3. PU/PVC release paper coating lines
The coating lines are to coat PU or PVC base on release paper by coating blade or roller, and form continuous and homogeneous coating layer after drying in the oven. The coating layer will be added a layer of adhesive, and then laminated with backing fabric or PU/PVC base. At the lamination step, release paper is peeled off and can be re-used to the next coating process. Any design or texture on release paper is duplicated to the surface of the finished synthetic leather.
4. Embossing machines
These engraved cylinder embossing machines are intended to print any kind of design on PU/PVC artificial leather surface. Any imitation of animal skins, any patterns, any glossy, plain, semi-matt effect can be obtained.
5. Printing machines
Printing machine is mainly used for coloring, printing, glossing and flatting, etc., which will increase the sense of beauty and genuine leather effect.
6. Sueding machines
Sueding machines mechanically abrades PU leather to raise or create a fibrous surface. This fibrous surface improves PU leather appearance, gives PU leather a softer, fuller hand, and can mask PU leather construction and subdue coloration. These improved aesthetics can increase the value of PU leather in the marketplace.
7. Tumbling machines
These machines are designed in a way that artificial leather is rotated in a cylinder so that the artificial leather is randomly twisted, rubbed with itself, cylinder wall, and plates embedded in the cylinder. The processing adds wrinkles and enhances soft hand feeling significantly.