Rail Pad Semi-Auto Upgrade +150% Daily Output

The customer is a small and medium-sized rail pad manufacturer in Hebei with long-term focus on polyurethane rail elastic pad production. The original fully manual process faced triple challenges: rising labor costs, product qualification rate consistently below 80%, and daily output under 100 pieces. Limited by narrow workshop space and tight renovation budget, the factory could not implement large-scale automation transformation. After two rounds of on-site surveys, Haifeng Polyurethane Machinery customized a lightweight semi-automatic upgrading solution featuring a compact rotary disc production line, patented pouring technology and simplified human-machine interface. After reconstruction, the factory realized the transformation from fully manual to semi-automatic standardized manufacturing, with daily output rising from 80 to over 200 pieces and product qualification rate stabilizing above 99%. The upgrade successfully consolidated existing railway bureau client cooperation and expanded new order sources.

This project delivered a compact rotary disc semi-automatic polyurethane foaming production line. The core equipment is an integrated compact solution combining an automatic batching system, patented pouring unit and multi-station rotary disc forming line. The rotary disc adopts split modular design for separate transportation and on-site assembly, eliminating the need for wall demolition or overall workshop layout readjustment. The whole reconstruction requires only one day of power connection shutdown, minimizing interruption to daily production. The circular disc structure maximizes the utilization of limited floor area, with multi-mold stations working in circulation to raise continuous forming efficiency.

The line is equipped with Haifeng’s self-developed low-tolerance pouring nozzle patent (Patent No.: ZL 201611168678.6). The optimized flow channel structure controls raw material feeding accuracy, effectively reducing manual weighing deviation and realizing uniform mixed foaming. Finished rail pads steadily meet the performance requirements specified in TB/T 3396. The system also supports halogen-free low-smoke polyurethane raw materials, complying with environmental and fire protection requirements of modern rail transit projects.

A full Chinese touch control screen features simplified visual operation logic; core functions are labeled with plain language such as “Start Batching” and “Pause Pouring.” Haifeng technical engineers provided two days of on-site targeted training for the factory’s senior operators. After guided trial production of two batches, workers could independently complete full-process operation. After upgrading, each production line only needs 2 core workers, responsible for mold demolding and offline quality inspection respectively. Labor demand is cut in half. The equipment interface retains parameter recording functions to generate complete batch production data, supporting railway bureau quality traceability audits. We provide a 12-month full-machine free warranty. A regional spare parts warehouse is established within Hebei Province. Most minor mechanical faults can be fixed on the same day, ensuring stable order fulfillment.