The Turkish client is a well-established automotive filter manufacturer based in Bursa — the heart of Turkey’s automotive industry. Supplying both the domestic aftermarket and export channels across Europe and the Middle East, the company faced increasing pressure to automate its cabin filter production. Their semi-automatic line relied on 7–8 operators per shift and struggled with inconsistent edge banding on charcoal composite media, especially during peak summer demand when dust and pollen filtration requirements spike.
They issued an RFQ for a fully automatic cabin filter machine with:
- Quick mold changeover (under 30 minutes) between popular Turkish-market models (Renault Clio, Ford Transit, Fiat Tipo)
- Precise hot-melt gluing for activated carbon and HEPA media
- CE-compliant electrical design and Turkish-language HMI
- 400 V / 50 Hz compatibility
2. Solution & On-Site FAT
Hengchao delivered a modular green-and-white aluminum-framed production line. During the Factory Acceptance Test (FAT), the Turkish technical team visited the Hengchao facility for live verification:
- Visual Inspection: The machine’s bright green enclosure with a circular observation window and warning tower light allowed the Turkish engineers to stand right beside the line, closely monitoring the automatic cycle and safety systems.
- Precision Debugging: While the clients observed, the Hengchao engineer fine-tuned the internal glue dispensing and trimming mechanisms through the open panel. White trimmed edges on the green workshop floor confirmed 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 3-layer activated carbon media.
3. Cooperation Process
- Sample Testing: 500 pcs trial on charcoal media simulating European dust/pollen conditions; Cpk data shared for edge alignment and glue bead consistency.
- FAT: Turkish engineers verified the 300×300 mm standard cabin filter running at 91% OEE. Turkish-language HMI labels and 400 V / 50 Hz wiring (IEC 60204 compliant) confirmed on-site.
- Compliance Pack: CE documentation, ISO 9001 certificate, spare parts list, PLC backup, and operation manual in Turkish/English.
- Commissioning: Shipped to Bursa, 5-day on-site installation, plus hands-on training for local operators on pleating tension, glue temperature control, and mold change procedures.
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 Renault Clio and Ford Transit filter sizes.
- Output: ~500 pcs/h sustained production.
- Client Testimonial:“Standing beside the Hengchao line during FAT, we could see the precision and robust build. The green-framed machine handled our charcoal media flawlessly — edge banding is finally stable. The Turkish HMI and local voltage made integration seamless.”— Production Manager, Turkish Client
5. Follow-up
After 6 months of stable running in Bursa, the client placed a second order for a standalone rotary pleater to upgrade an older line, and is evaluating a PU-frame cabin filter module for 2026 EV projects.
