Semi-Automatic PU Rail Pad Casting Line Upgrade in China

Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

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.

Planning a related production line

This record concerns a rail-pad casting configuration. For another rail component, the material system, mold population, handling cycle and qualification tests must be reviewed against the new drawing. Project figures are specific to this record.

Production brief for technical discussion

Provide a finished-product drawing or sample, material data, target output, automation needs and factory conditions. Haifeng will review the process, equipment interfaces and acceptance plan for your own production goals.

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.