Compact Structure
Small footprint, flexible layout, suitable for a variety of factory spaces.
Efficient Operation
Automatic rotary workbench to achieve continuous production.
Manpower & Labor Saving
Automatic injection and demoulding to reduce manual operations.
Carousel Sole/Insole Production Line
The Carousel Sole/Insole Production Line is an efficient and automated PU sole molding system. It adopts a rotary station layout, supports multiple molds to operate simultaneously, and realizes continuous casting and molding.
The entire line consists of a foaming machine, a disc turntable, a mold system, a temperature control system and a demoulding station. It is suitable for the production of multiple types of soles such as sports shoes, casual shoes, and safety shoes.
The production line has a compact footprint, is easy to operate, and has a high degree of automation. It is widely used in mass production scenarios in medium and large shoe factories.
Specification Of Carousel Sole/Insole Production Line
Turntable cable diameter | Customizable |
Number of Workstations | Within 80 stations |
Height of the turntable line from the ground | 400 mm |
support wheel | 20 |
running speed | Adjustable from 4 to 12 minutes per revolution |
driving mode | Reduction unit |
Reducer power | 5.5 kilowatts |
Load capacity of the center support | 3 0 t |
Disk loading | 3 0 t |
Thickness of rotating line steel plate | 6mm |
Wire skeleton of a turntable | 10 mm I-beam (national standard) |
steel track plate | 16 mm steel plate |
Components Of Carousel Sole/Insole Production Line
Mold Bases
The pneumatic formwork system consists primarily of the lower mold base, support plate, upper mold base, mold opening cylinder, clamping pin, clamping cylinder, clamping air bag, guide rod, safety pin cylinder, compression spring, pneumatic control valve, connecting shaft, and other components, as well as an electrical control box. The main body of the formwork system is machined and formed by section steel welding, making it both firm and beautiful.
| Loading template size | left and right 800 mm Front and rear 900 mm |
| Closed mold height | to be determined |
| Clamping force | up to 4000kgf |
| Airbag stroke | 30 mm |
| Air source pressure | cylinder air source 0.6-0.8Mpa |
| Air bag air source | 0.2- 0.3Mpa |
| Solenoid valve control voltage | DC24V |
Polyurethane Sole/Insole Molds
- The mold uses pneumatic opening and closing to reduce labor and costs, and reduce waste caused by operation.
- The mold uses circulating water heating, which saves more than two-thirds of energy consumption compared to traditional methods, and the mold temperature is controlled within ±2℃.
- High-precision processing: CNC precision processing technology is used to ensure that the sole details are clear and the molding size is consistent.
- Diversified design: Single-cavity or multi-cavity molds can be customized to suit different styles of sports shoes, casual shoes, safety shoes, etc.
- Mold split structure: Convenient demoulding and cleaning, support semi-automatic or fully automatic demoulding equipment for use.
Robot Arm
- Precise pouring: The robot arm automatically controls the movement and positioning of the foaming head to ensure accurate and uniform injection of raw materials.
- Efficient operation: It can continuously and quickly pour multiple stations, greatly improving production efficiency.
- Synchronous control: It is linked with the foaming machine and the disc platform to unify the operation rhythm and ensure smooth rhythm.
- Reduce labor: Replace manual pouring, reduce labor intensity, and reduce human errors.
| Robot model | GP180 | GP12 |
| Degree of freedom | 6 | 6 |
| Horizontal extension | 2702mm | 1440mm |
| Transportable mass | 180kg | 12kg |
| Main body mass | 1020kg | 130kg |
| Repeat positioning accuracy | ±0.05mm | ±0.02mm |
| Controller | YRC1000 | YRC1000,YRC1000micro |
| Protection level | Main body: IP54, wrist axis: IP67 | Main body: IP54, wrist axis: IP67 |
| Installation method | Floor mounted | Floor-mounted, wall-mounted, inverted, tilted |
| Purpose | Transportation, picking/packaging, palletizing, assembly/disassembly | Transportation, picking/packaging, palletizing, assembly/disassembly |
Mold Temperature Controller
- Precise temperature control and sensitive response: PID control algorithm is used to automatically heat or cool the medium to achieve precise adjustment of mold temperature.
- Wide voltage input: supports AC85~265V wide range input, suitable for most power grid environments in the world.
- Multiple temperature protection functions: built-in high temperature alarm, low temperature alarm, heater overheat protection, excessive temperature difference alarm, etc.
- Multi-signal acquisition: supports K-type thermocouple input, and can simultaneously monitor water inlet temperature, water outlet temperature, and pump current.
- Fault self-check and alarm: It has 11 error code alarms (such as lack of liquid, reverse phase, sensor failure, etc.), and has sound and light alarm and display functions.
- Intelligent operation status display: The front panel LED indicates the current operation status, including heating, cooling, operation, fault and other modes.
- Humanized operation interface: supports multiple user functions such as timed power on and off, temperature unit switching, operation timing, parameter locking and recovery.
Polyurethane Raw Materials
- Slow rebound, fits the neck curve, and improves comfort;
- Adjustable density (commonly 40-60 kg/m³), taking into account both support and softness;
- After the raw materials are mixed, the reaction is stable and the foaming is uniform, which is suitable for mold casting production;
- Environmentally friendly and odorless formulas can be selected, which meets the environmental protection requirements of the European and American markets for VOC release.
Low Pressure PU Foam Machine
Applicable material viscosity （22℃) | POLYOL～3000CPS ISO～1000MPas |
Injection output | 26-120g/s |
Mixing ratio range | 100：28～48 |
Mixing head | 2800-5000rpm, forced dynamic mixing |
Tank Volume | 120L |
nitrogen requirement | P：0.05MPa |
Temperature control system | Heating: 2×3.2Kw |
input power | three-phrase five-wire ，380V 50HZ |
rated power | about 11KW |
Volume | 4100(L)*1250(W)*2300(H)mm, swing arm included |
Customer Cases Of Carousel Sole/Insole Production Line
A footwear manufacturer located in northern India purchased a 24-station disc shoe production line configured by our company to improve the production efficiency and consistency of PU soles. The whole line is equipped with a high-pressure foaming machine, an automatic rotating disc platform, a mold temperature control system and an auxiliary demoulding device, which is suitable for the mass production of safety shoes and casual shoe soles. The customer adopts a two-shift production mode, and the daily output is stable at 3,500 to 4,000 pairs. The equipment runs smoothly and is easy to operate, which significantly reduces labor input and improves the consistency of finished products. After the project was put into production, the customer highly praised the degree of automation and mold compatibility of the whole line, and plans to expand the second disc line in the next two years to meet the market growth demand.After installation and commissioning, the customer highly recognized the stability of the equipment and the consistency of the finished product, and plans to introduce a second production line in the next stage to further expand production capacity. This project also successfully helped the customer to expand the brand influence of customized memory pillows in the North American market.
After the equipment was delivered, the customer quickly completed the installation and commissioning. At present, it has achieved a stable output of more than 1,000 pieces of seat foam per day. It highly praised the efficiency and operating experience of the equipment, and continued to negotiate with us for cooperation on the second production line.
