Ultra-Hard Filler Casting Technology: Solving a 20-Year Industry Wear Challenge
In the polyurethane composite manufacturing field, high-friction abrasion between ultra-hard fillers and equipment chambers has long been a persistent challenge. Traditional machines typically require part replacement every three months, with annual maintenance costs exceeding ¥120,000 per unit.
Feilong Polyurethane Equipment’s 2024 patented technology tackles this issue through a revolutionary fluid redesign — embedding diamond-shaped guide blocks within the mixing blades. This innovation redirects material flow from radial impact to axial spiral motion, extending continuous operation time from 800 to 1,500 hours, reducing downtime losses by over ¥500,000 annually for a mid-sized enterprise.
This breakthrough is powered by three key innovations:
- Fluid Dynamics Optimization – The helical channel formed by guide blocks reduces local flow velocity from 12 m/s to 7 m/s.
- Wear-Resistant Material Innovation – Tungsten carbide–cobalt alloy coating (HRC 65) doubles blade lifespan.
- Smart Feedback System – Vibration sensors monitor wear in real time, while the PLC control system automatically adjusts rotational speed, maintaining formulation precision within ≤ 0.8%.
The newly developed deviation-coupled metering pump system further redefines control accuracy. By introducing proportional factors and velocity compensators, it controls dynamic mixing errors within ± 0.5%, improving precision by 40% compared with standard PID systems.
Feilong’s flow-compensated, anti-clog continuous casting system adopts a floating mechanical seal structure, achieving zero leakage even at 1,500 rpm, and operates across a –40 °C to 120 °C temperature range (error < ± 2 °C), fully meeting stringent military-grade uniformity standards.
The hybrid electro-hydraulic casting machine integrates traditional hydraulic drive with servo-motor control, achieving a minimum output of 0.05 g/s and a flow regulation ratio of 1:1000, making it ideal for bio-based polyurethane micro-formulation research.
Efficiency Revolution: From Single-Machine Performance to Industry-Wide Transformation
At a rail-transit component plant, two workshops offer a striking contrast:
- Workshop A (using Feilong’s fully automated line) achieved 98.7% yield and 0.32 kW·h/kg energy consumption.
- Workshop B (using traditional machines) showed only 81.3% yield and 0.51 kW·h/kg.
This performance gap reflects Feilong’s end-to-end intelligent control system, redefining manufacturing efficiency and product consistency.
Feilong’s influence extends beyond the factory floor. As the Chair Unit of the Polyurethane Equipment Committee under the China PU Industry Association, the company led the drafting of the “Polyurethane Elastomer Casting Machine” group standard — introducing 12 mandatory benchmarks including precision and energy efficiency. This new standard raises industry entry thresholds and accelerates the elimination of outdated capacity.
At the intersection of carbon neutrality goals and the new materials revolution, Feilong Polyurethane Equipment continues to expand into the new energy sector. Its latest bio-based polyurethane foaming line increases castor oil derivative conversion rates to 92%, enabling a 30% weight reduction in lightweight automotive components.
Amid national building insulation standards tightening to 0.018 W/(m·K) and EV battery insulation demand rising by 25% annually, Feilong’s “Equipment Innovation → Material Breakthrough → Application Expansion” strategy is driving the polyurethane industry’s evolution from scale growth to value creation.
