Sports Brand Insole Line Upgrade +300% Daily Output

The customer is a leading domestic sports brand with over a decade of focus on the sports footwear market. To meet consumers’ higher demands for foot protection and sports comfort, the brand planned to launch a premium functional insole product line with high resilience, strong arch support, breathability and antibacterial performance. In the early stage, the brand adopted traditional manual and semi-automatic production workflows and encountered three prominent pain points: over 90% of products were single-density insoles, unable to satisfy complex functional demands such as multi-layer composite structures and orthotic arch support; raw material waste rate hit 8% with obvious dimensional deviation; maximum daily output per line was merely 3,000 pairs, failing to support its annual sales target of over one million pairs. Haifeng Polyurethane Machinery customized a full-process insole production solution based on the HF-LPM-2A1B-F low pressure foaming machine, targeting three core objectives: functional product upgrade, production efficiency improvement and comprehensive manufacturing cost optimization.

This project delivered a complete polyurethane insole full-process production solution. The core equipment is the Haifeng HF-LPM-2A1B-F low pressure foaming machine (3 supporting production lines), equipped with an optional dual-density material supply module and 6-cavity mass-production metal molds. It supports flexible manufacturing of single-density, dual-density and composite substrate functional insoles, with casting mode as mainstream and spraying function reserved for composite surface lamination.

The machine features built-in vacuum defoaming system for raw material tanks, a self-cleaning anti-blockage mixing head with adjustable flow range of 26–120 g/s (stably locked at 30–85 g/s for small-dose insole pouring), and fast color & formula switching completed within 3–5 minutes. The PLC touch screen stores more than 500 independent production formulas, enabling one-click parameter switching for different insole densities (30–50D) and hardness grades. The metering system maintains consistent precision of ±0.3% to stabilize mixing ratios and dimensional consistency.

Automated auxiliary matching units include a robotic arm automatic pick-up mechanism, raw material preheating & dehydration pretreatment tanks, CNC automatic trimming machines and multi-dimensional offline quality inspection stations, forming a fully closed-loop intelligent production chain. Haifeng assisted in optimizing A/B component mixing formulas and foaming parameters, developed custom 6-cavity dedicated molds, and completed on-site installation and parameter commissioning within 3 working days. A trial batch of 5,000 pairs was manufactured to verify long-term process stability. Standardized hands-on operation training was provided, and operators could master full machine operation after only 2 hours of practical learning.