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PU/PVC Synthetic Leather Making Plant

 

1.  Introduction
Synthetic leather was first produced near the turn of the century. The insufficient supplies and high cost of genuine leather brought about the demand for synthetic leather. Synthetic leather has gradually replaced genuine leather in many fields. Over the past few decades, the demand for high quality synthetic leather has increased tremendously.
Though there is a number of materials are used to produce synthetic leather, PU and PVC remain the most commonly used in the market. PU synthetic leather is more flexible and has a much higher tensile, tearing and bursting strength. Further more, whereas PVC synthetic leather can only be used to make items with a low stress tolerance, PU synthetic leather can be used to make a wide variety of products which must be made from strong materials with a high stress tolerance such as boots, shoes bags, luggage, belts, gloves, and upholstery for furniture and car seats.


2.  General process Information
2.1  Application of Product

2.1.1 ESPECIALLY IN CLOTHES.
2.1.2 FURNITURE, PURSE.
2.1.3 SHOE’S MATERIAL.
2.1.4 SOFE LEATHER MATERIAL.

2.2  Description of Process
The process is a PU sheet formed and then laminated onto the base cloth. This is done by coating release paper with a layer of a mixture containing MEK, EA solvents and PU resin. The paper is dried in an oven at 100℃. It is then recoated with the same substance and again dried in an oven. This time at 110-140℃. This sheet of PU is then laminated onto the base cloth. At this point the paper on which the PU was formed is released. The release paper may be used up to 10 times. It should, none the less, be inspected for tears each time it is used. This product is highly valued in the garment, shoe, luggage, and industries since the feel and even the smell are much closer to genuine leather.

2.3  Flow chart


3.  Plant Description
3.1  Production Capacity
3.2  Raw Materials

3.2.1 Base cloth
3.2.2 PU resin
Specification
One-component resin
Two-component resin
Surface treating solution
3.2.3 PU pigments
Powder pigments
3.2.4 Solvent
MEK, Toluene, DMF
3.2.5 Release Paper

3.3  Machinery & Equipment

ITEM
DESCRIPTION OF EQUIPMENT
Q’TY
1.
Four section coating oven
1 SET
2.
Release paper inspection machine
1 SET
3.
Three colors surface treatment M/C
1 SET
4.
Embodying machine
1 SET
5.
Two state buffing machine
1 SET
6.
Material mixing equipment
1 SET
7.
Product inspection machine
1 SET
8.
Fabric inspection machine
1 SET
9.
Hot oil temperature control system
1 SET
10.
Dop recycling equipment
1 SET

3.4  PLANT WORKER REQUIRED REFERENCE LIST




Job Description
Person
General Manager
1
Plant Manager
1
Production Technician
17
Operator
104
Quality Controller
5
General Worker
8
Driver
 
Total
136

3.5  Inspection and Testing Equipment
Item
Set
Tensile
1
Bursting
1
Flexco Meter Tester
1
Aging Tester
1
Viscosimeter
1
Release Paper Separating and Inspecting Machine
1
Production Inspecting Machine
1
Cloth Inspecting Machine
1

3.6  Utility
Item
Description of equipment
Q’TY
Circulation
Cooling
Water
M3/min
Air M3/MIN
Power
KW
Machine
Weight
TON
Foundation
Load
T/M2
Hot oil
KCAL/H
1
Four section coating oven
1 set
1.6
1.5
360.0
130.0
1.0
1840.0
2
Release paper inspection machine
1 set
--
0.1
6.5
3.0
1.0
--
3
Three colors surface treatment M/C
1 set
0.36
0.5
58.0
45.0
1.0
160.0
4
Embodding machine
1 set
0.6
0.2
115.0
35.0
1.0
80.0
5
Two state buffing machine
1 set
0.4
0.2
95.0
30.0
1.0
--
6
Material mixing equipment
1 set
--
1.0
186.0
50.0
2.0
--
7
Product inspection machine
1 set
--
--
4.4
3.0
1.0
--
8
Fabric inspection machine
1 set
--
--
3.4
2.0
1.0
--
9
Hot oil temperature control system
1 set
--
--
70.0
--
0.5
--
10
Dop recycling equipment
1 set
1.3
1.0
82.0
42.0
1.5
--
 
TOTAL
 
4.26
4.5
991.2
--
--
2080.0


3.7  Plant Site Planning
The selection of a PU leather plant site should take the following variables into consideration:
3.7.1 Sufficient and convenient supply of materials.
3.7.2 Low utility rates.
3.7.3 Location in or near an industrial area.

3.8  Land and Plant Ste Area
3.8.1 Factory : 30m X 100m =3000 M2
3.8.2 .Warehouse : 30m X 30m =900 M2
3.8.3 Office,Lab,Ets : 30m X 15m =450 M2
3.8.4 Plant Total Area : 4350 M2


4.  List of Suppliers
Forward Machinery Industrial Corp.
No.8 Kuo Tai Rd. 14 Lin Ta Li.
Chu-Nan Miao-Li Taiwan
Tel:886-37-465137
Fax:886-37-470149
E-Mail:f465137@ms16.hinet.net

Sponsored by the Bureau of Foreign Trade (BOFT)   Administered by the Taiwan External Trade Development Council (TAITRA)
333 Keelung Rd., Section 1, 5-7 Fl., Taipei 11003, Taiwan ROC
Tel: +886 (2) 2725-5200     Fax: +886 (2) 2757-6245     E-mail: taitra@taitra.org.tw
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