The Kazakh client is a fast-growing filter manufacturer in Kostanay, supplying the local aftermarket and OEM assembly lines (including Hyundai Trans Kazakhstan and Allur Auto). With Kazakhstan’s extreme climate — long, dusty summers and freezing winters — demand for high-efficiency cabin filters is rising fast. Their challenge was heavy reliance on manual assembly: edge banding deviation on charcoal media, inconsistent glue beads, and 6–8 operators per shift. They needed a stable, automated cabin filter machine with quick changeovers (under 30 mins) and precise hot-melt gluing.
2. On-Site Verification (FAT) & Solution
We delivered a modular green-and-white aluminum-framed production line. During the FAT, the Kazakh technical team visited our facility for live testing:
- Visual Inspection: The machine’s bright green enclosure with a circular observation window and warning tower light allowed the Kazakh engineers to stand right beside the machine, closely monitoring the automatic cycle and safety systems.
- Precision Debugging: While the clients observed from the side, our engineer fine-tuned the internal glue dispensing and trimming mechanisms. White trimmed edges visible on the green workshop floor proved the cutting station’s accuracy.
- Key Stations: Servo pleating → Hot-melt frame bonding → Auto edge banding → Precision trimming.
- Specs: Handles 150–400 mm lengths; cycle time ≤ 7 seconds/pc; compatible with standard non-woven, HEPA, and activated carbon media.
3. Cooperation Process
- Sample Testing: 500 pcs trial on charcoal media simulating Kazakh dust conditions; shared Cpk data for edge alignment.
- Factory Acceptance (FAT): Kazakh engineers verified the 300×300 mm standard cabin filter running at 91% OEE. Russian-language HMI (widely used in Kazakhstan) and 380 V / 50 Hz wiring confirmed on-site.
- Commissioning: On-site installation in Kostanay, plus 5-day hands-on training for local operators on pleating tension and mold changes.
4. Results & Feedback
- Efficiency: Labor reduced from 8 to 2 operators/shift; reject rate dropped from 3.8% to 0.6%.
- Flexibility: 28-min changeover between Hyundai Tucson and Kia Cerato filter sizes (both assembled locally in Kazakhstan).
- Client Testimonial:“Standing next to the machine during FAT, we could see the precision and stability. The green-framed line handled our charcoal media perfectly — no more edge banding nightmares. This is exactly what our Kostanay plant needed.”— Production Manager, Kazakh Client
5. Follow-up
After 6 months of stable running in extreme-temperature testing, the client placed a second order for a standalone rotary pleater to upgrade an older line, marking a long-term partnership in Central Asian automotive filtration.
