2024-01-08
Client: Well-known IBC Chemical Drum Manufacturer in Brazil. (R*FT EM**LAG**S COMPANY)
Project Background:
The client company was established in 1978 and is a leading company in Brazil specializing in the production of IBC tank, water drums, and oil drums. Due to increasing market demands, their existing equipment is insufficient to meet current production requirements. Previously, they relied entirely on fully automated cage frame production line imported from Italy. However, due to the lengthy production cycles in Italy, the client turned to Chinese enterprises to seek alternative automated production lines. They requested us to optimize the functionality of the production line based on the Italian design and provide a more efficient and convenient production method. We were tasked with customizing a production line from raw materials to finished products based on their samples and production volume requirements, aiming to produce 500-600 products per day (8 hours).
Project Progress:
In May 2023, the client came across our company's fully automated IBC cage line via Hwashi's YouTube channel, finding it perfectly aligned with their requirements. They initiated contact with our sales representative through online communication software to seek further detailed information and a quotation. Hwashi promptly organized an online project communication group, involving senior management and the engineering design team. Through discussions, we learned that the client's IBC cage differs from those produced by Chinese enterprises, utilizing 18mm round tubes for both long and short pipes, achieved through embossing to facilitate welding. Currently, the client lacks equipment to emboss the pipes, relying on imports for all tubing, resulting in significantly high material costs. To address this, our engineering team tailored a complete production line from raw material processing to frame formation, incorporating automatic leak testing and stacking, meeting the client's specific requirements.
https://youtu.be/VTvKCELk1bM
The Tube Manufacturing Process:
1.Seamless welding of round tubes using a tube milling machine; capable of cutting based on specified lengths.
2.Utilizing a fully automated long tube forming machine for automatic loading/unloading, end shrinking, and forming of round pipes; capable of forming two pipes at once, with forming completion within 12-15 seconds.
3.Utilizing a fully automated short tube pressing machine for pressing and cutting round pipes; capable of embossing two long pipes and cutting them into four short pipes simultaneously, with embossing and cutting completion within 12-15 seconds.
4.Automatic pressing, end shrinking, bending, and cutting of base frame tubes: capable of achieving a fully automated base tube production process, completed within 12-15 seconds.
Framework Production Process:
1) Mesh frame welding - bending - clinching - punching - discharging - welding of metal base frame - automatic metal base frame discharging - loading of base panel - manual screw fixation of frame and bottom frame.
2) Inner tank transfer - automatic valve screwing or welding - automatic leak detection - inner tank fitting into frame - manual fitting of pull rods - stacking of finished IBC tote.
Due to the 12-hour time difference between Brazil and China, Hwashi's sales team and engineering team actively coordinated with the client's working hours. Utilizing online communication software and video conferences streamlined technical discussions, eliminating delays in confirmation. After thoroughly understanding all requirements, our company provided a customized technical proposal and quotation to the client within 24 hours. The client was highly satisfied with our efficient communication and professional technical solutions. Our equipment offered excellent value compared to Italian counterparts, and our delivery time was significantly faster than that of European equipment.
After a month of discussions and confirmation, the client, without physically visiting China, signed a contract online with us for a complete set of automated IBC cage frame production lines, valued at approximately $900,000. Within a week of signing the contract, they made a 50% down payment. In compliance with the contract, Hwashi completed the production and delivery of all equipment within three months. The client conducted feasibility inspection of each machinee via online videos and ultimately produced 30-50 qualified products continuously as acceptance criteria. All equipment passed the acceptance test in one go.
Due to the successful progression and delivery of this project, the client highly appreciates Hwashi Company. They are willing to entrust more customized projects to the Hwashi team. Currently, negotiations are ongoing for the second batch, specifically an automated stacking and packaging assembly line for oil drums.
If you also have a need for customized automated production lines, please feel free to contact us at any time. We believe our expertise can help you achieve cost reduction, efficiency improvement, and generate more profits.
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