The great pressure of nitrile glove market competition forces glove manufacturers to find a way to reduce costs so that they can achieve a small profit. Fengwang, for nitrile glove production line rate reduction and efficiency problem, put forward the following scheme.
1. Raw Material Optimization
1> The raw material of nitrile gloves is nitrile rubber (NBR) and a series of chemical reagents, and the proportion of chemical reagents is adjusted to reduce the cost under the premise of ensuring the gloves’ tensile property and chemical resistance.
2> Sign long-term agreements with suppliers by centralized procurement of raw materials as far as possible, and purchase futures to avoid market price fluctuations affecting costs.
3> Recycle the waste corner material of the production line and reuse it for the production of low-end gloves such as industrial gloves, after treatment. The glove former design can also be optimized to reduce waste.
2. Production Process Optimization
1> Hand mold impregnation process optimization. Multi-layer impregnation techniques, such as double-tank impregnation, are used to improve production efficiency. In addition, the impregnation time and temperature are optimized to reduce the waste of rubber material.
2> Use high high-efficiency vulcanization system. To reduce curing time and increase productivity. Optimize oven temperature curve to avoid excessive vulcanization conduction energy consumption increase.
3> Improve the surface treatment technology of ceramic hand molds to reduce the dependence on release agents and reduce subsequent cleaning costs.
4> Optimize the production process machine. Manual operation is replaced by an automatic edging machine, thus reducing labor costs. Using fully automatic glove packaging machines for automatic counting, packaging, and sealing reduces labor costs and saves time.
3. Optimize Energy Equipment
1> Optimize oven device. An efficient hot air drying circulation system is adopted to reduce the energy consumption of the oven. Use variable frequency motors so that power can be adjusted according to production needs, reducing power waste.
2> Maintain the device regularly. Regular maintenance is an effective way to reduce production costs. For example, regular maintenance of key production machines such as immersion tanks and vulcanization furnaces, can reduce the downtime of nitrile glove production lines.
3> Real-time monitoring. Using the most advanced IoT detection equipment status, early warning of failure so that no waste of raw materials and energy.
4> Flexibility of production. The same production line can quickly switch to different specifications (thickness, color) of gloves, reducing mold change time.
4. Automated Quality Inspection
The visual detector is a professional intelligent machine for detecting glove pinholes, replacing manual quality inspection, and effectively improving the detection speed and reducing the rate of missed detection.
5. Regular Personnel Training
Regular operator skills training to reduce errors and downtime and the risk of operational errors.