KPU Shoe Upper Production Line Complete Solution
Full set of turnkey production solutions for KPU polyurethane shoe upper manufacturing
KPU Shoe Upper Production Line Complete Solution This turnkey production solution is provided by Haifeng Polyurethane Machinery. Our integrated KPU shoe upper production line is widely used for sports shoes, casual shoes, safety shoes and outdoor shoe uppers, featuring high metering accuracy, stable operation, low defect rate and full-process automation.
1 Core Advantages of This Production Line
- Dual precision metering system, long-term ratio stability, effectively reduce batch defects
- Complete closed-loop production, high overall efficiency, 3/6 station optional for different output demands
- Full temperature & pressure linkage control, avoid foaming deviation caused by ambient changes
- Modular design, easy installation, maintenance and partial upgrade
- Compatible with multiple molds and formulas, strong production flexibility
1.1 Raw Material & Basic Technical Settings
Adopt two-component KPU polyurethane system: Component A (Polyester Polyol) + Component B (Isocyanate), color paste is optional.
- Mixing ratio: 100 : 85 ~ 110
- Raw material preheating temperature: 30 ~ 40℃ (special drying oven required)
- Auxiliary materials: Release agent, pigment, Methylene Chloride (mixing head cleaning), DOP (tank cleaning)
- Conventional instantaneous flow: 10 ~ 30 g/s | Max flow for special working condition: 70 g/s
- Metering accuracy: Standard ±0.1% | High-precision customized: ±0.5‰ (0.05%)
- Control mode: Manual / Semi-automatic via HMI touch screen
- Station configuration: 3 stations / 6 stations optional
- Heating mode: Water heating (for normal temperature workshop); Oil heating (for low-temperature workshop)
- Raw material storage: Store in sealed warehouse, humidity ＜45%, keep away from open fire
1.2 Production Capacity & Benefit Data
Calculated based on 8-hour daily working hours:
| Mold Type | Single Cycle Time | Hourly Output | Daily Output |
|---|---|---|---|
| 2-cavity mold | 5 ~ 8 min (Average 6.5 min) | 18 ~ 22 pcs | 144 ~ 176 pcs/set |
| 4-cavity mold | 5 ~ 8 min (Average 6.5 min) | 36 ~ 44 pcs | 288 ~ 352 pcs/set |
1.3 Standard Production Process
Complete 9-step closed-loop production flow:
- Raw material preheating: Heat materials to standard temperature via drying oven
- Batching & stirring: Mix A/B components evenly on stirring station
- Release agent spraying: Prevent product adhesion
- Filling & vacuum defoaming: Vacuum degree -0.08 ~ -0.09 MPa to eliminate air bubbles
- Primary plasticizing: Semi-curing through heating tunnel
- Fabric lamination: Hot press bonding with shoe mesh fabric
- Full curing: Curing temperature 60 ~ 80℃, complete shaping in aging oven
- Inspection & mold maintenance: Finished product inspection, mold cleaning & maintenance
- Empty mold return: Empty molds circulate to the starting position for next batch
1.4 Full Equipment List
| No. | Equipment Name | Quantity | Overall Dimension (mm) | Equipment Image |
|---|---|---|---|---|
| 1 | KPU Raw Material Preheating Oven | 1 set | 1000×800×1500 |  |
| 2 | KPU Stirring Workstation | 1 set | 1000×800×1100 |  |
| 3 | High-Speed Vacuum Defoaming Machine | 1 set | 1800×1000×2000 |  |
| 4 | Mold Return Line | 1 set | 3000×800×1000 |  |
| 5 | Curing Tunnel Line | 1 set | 3500×800×1200 |  |
| 6 | KPU Forming Machine | 1 set | 2000×800×2350 |  |
| 7 | Mold Treatment Cabinet | 1 set | 800×600×1500 |  |
| 8 | Aging Oven | 1 set | 1700×1360×2050 |  |
| 9 | Material Turnover Cart | 1 set | 1200×800×1800 |  |
| 10 | Release Agent Spray Gun | 1 set | 105×155 |  |
1.5 Core Component Configuration
- Metering & Casting System: 20cc servo metering pumps for A/B material (1.3KW motor + planetary reducer); 0.6cc color paste pump (0.75KW, 50L tank); Needle valve mixing head with independent cooling
- Temperature Control System: Water heating unit, independent tank temperature control, 2HP chiller for mixing head
- Cleaning System: 20L dedicated cleaning tank
- Control System: Inovance H3U PLC + Kunlun 10-inch touch screen, Delixi electrical, Inovance sensors
- Spray Gun: Model MRS-R/F, working pressure 2.0Mpa, weight 320g
- Auxiliary Equipment: Air storage tank, industrial chiller, air compressor
2 Detailed Technical Parameters
2.1 Mold
Material: Aluminum alloy / Cr12MoV alloy tool steel
2.2 Raw Material Oven
Model: XHG×3-2.5, Volume: 2.5m³ Max temperature: 90℃, Automatic temperature control, Total power: 6.55KW
2.3 KPU Forming Machine
Drive mode: Hydraulic Voltage: 220V / 380V Power: 30 ~ 50KW Standard: 3 working stations
2.4 Casting System
Max instantaneous flow: 70g/s Pump speed: 30 ~ 150 rpm Mixing head speed: 8600±150 rpm Power supply: 3-phase 380V / 50Hz Material barrel: Stainless steel, 120 ~ 220L (customizable)
2.5 Chiller
Power: 1.91KW, for mixing head & chamber cooling
2.6 Air Compressor
Power: 22KW, supply power for pneumatic & vacuum system
3 Workshop Environment & Safety Requirements
| Item | Requirement |
|---|---|
| Workshop Space | Flat floor, overall size about 8m × 6m |
| Ambient Temperature | ≤40℃, no condensation |
| Power Supply | 3×380V ±5%, 50Hz, reliable grounding |
| Supporting Facilities | Compressed air, circulating water, good ventilation |
| Operation Safety | No open fire; Operators wear solvent-resistant gloves & gas masks |
| Operators | 4 ~ 6 trained professional workers |
4 Power Consumption
- Main equipment total installed power: About 34KW
- Auxiliary equipment total power: About 25KW
5 Common Production Defects & Solutions
| Defect Phenomenon | Root Cause | Improvement Solution |
|---|---|---|
| Internal air bubbles | Insufficient vacuum degree | Adjust vacuum to -0.08 ~ -0.09 MPa, check sealing |
| Product sticks to mold | Uneven release agent spraying | Spray release agent uniformly before each cycle | Hardness deviation | Ratio drift / temperature fluctuation | Calibrate metering pump, stabilize raw material temperature |
| Surface pinholes | Raw material absorbs moisture | Seal material tank, control humidity ＜45% |
6 Optional Upgrades & Custom Configurations
- Automatic raw feeding system (reduce manual work)
- MES data connection (full production data traceability)
- Explosion-proof configuration (for special workshop)
- Multi-formula one-key switching system
- Export standard voltage & frequency customization
7 Delivery & Export Information
- Production Lead Time: 15 ~ 20 working days after deposit
- Packaging: Export standard fumigated wooden case
- Supporting Documents: Packing list, commercial invoice, CE/standard test report
- Shipping: Support sea, air and combined transportation
8 Frequently Asked Questions (FAQ)
- Q1: How to choose between 3-station and 6-station models?
A: 3-station for small batch & trial production; 6-station for mass production to improve efficiency. - Q2: Can mold material and cavity quantity be customized?
A: Yes, we customize molds according to your product drawings. - Q3: Is the equipment voltage adjustable for different countries?
A: Yes, we adjust voltage and frequency to fit local power grid. - Q4: Can this line produce different styles of shoe uppers?
A: Compatible with most sports, casual and safety shoe uppers, just replace molds and formulas. - Q5: What is the daily maintenance schedule?
A: Clean mixing head & spray gun daily; Check pressure/temperature per shift; Inspect pumps & pipelines every 30 days. - Q6: Do you provide supporting consumables?
A: We recommend matched release agent & cleaning solvent, and provide purchasing guide. - Q7: Can existing old lines be partially upgraded?
A: Yes, retain frame and upgrade metering & control modules to save cost. - Q8: Extra configuration needed for low-temperature workshop?
A: Add pipeline insulation if workshop temperature ＜15℃. - Q9: How to store unused KPU raw materials?
A: Store in sealed dry warehouse, humidity ＜45%, far away from fire source. - Q10: Can we switch different formulas quickly?
A: Optional one-click formula switching function.
9 After-Sales Service
- Technical documents: Operation manual, electrical drawings and layout drawings
- On-site service: Engineer installation & operator training
- Warranty period: 12 months warranty for non-artificial damage, free spare parts
- Long-term support: Lifetime technical guidance and spare parts supply after warranty
Contact Us
For detailed layout drawings, customized solutions, on-site surveys or business cooperation, please feel free to contact Haifeng Polyurethane Machinery:
