HC-エアキャビンフィルターサプライヤー
India’s car parc is dominated by compact hatchbacks and SUVs — Maruti Swift, WagonR, Baleno, Brezza, Hyundai i10/i20/Crema, Tata Nexon/Punch, Mahindra XUV300/XUV700. With rising PM2.5 levels in Delhi, Mumbai, Lucknow and Kolkata, Indian buyers no longer treat cabin filters as optional: service centers now push activated carbon, HEPA-grade and anti-pollution cabin filters as standard replacement items.
The Indian client ran a labor-heavy cabin filter cell:
- 7–8 operators per shift
- Manual pleating inconsistent across Swift / Dzire / Baleno sizes
- Glue overflow on activated-carbon media
- ~4.0% trimming reject
- No recipe system for 40+ SKUs
- HMI only in Chinese/English — local operators struggled
They wanted a high-SKU, India-ready cabin filter machine: 415 V / 50 Hz, Hindi + English HMI, stable hot-melt on charcoal media, and fast changeover between high-volume Maruti/Hyundai/Tata sizes.
2. Solution & FAT
Hengchao delivered the signature green-and-white modular cabin filter line with India configuration:
- Electrical: 415 V 3Φ / 50 Hz, VFD-tuned motors, wide-input control supply, IEC 60204-1 design, IP54 control cabinet for dusty Indian shop floors
- HMI: Hindi + English + Chinese, recipe storage by car model (Swift / Dzire / Baleno / Creta / Nexon / XUV300)
- メディア: non-woven, synthetic, HEPA/nanofiber, 2–3 layer activated carbon, anti-bacterial layer
- Stations: servo pleating → hot-melt side/end gluing → non-woven edge banding → precision trim → reject/outfeed
- Cycle: ≤ 7 s/pc on standard rectangular cabin filters; 150–400 mm length range
During FAT, the Indian production head stood beside the machine while the Hengchao engineer adjusted glue temperature, pleat height, and edge-band pressure through the circular observation window. White trims on the floor proved cutting accuracy; the charcoal pack came out without delamination or air-bypass gaps.
3. Cooperation Process
- Media test: 800 pcs on activated-carbon + synthetic blend simulating Delhi/NCR pollution load; Cpk shared for edge offset and glue width.
- FAT: Verified 235×200 mm Swift/Dzire cabin filter at 90%+ OEE. Hindi HMI labels, 415 V / 50 Hz wiring, e-stop/earthing per IEC 60204-1 reviewed on-site.
- Export docs: IEC 60204-1 electrical file, CE-design-basis declaration, operation manual in English + Hindi glossary, PLC backup, spare-parts kit, Indian BIS/electrical compliance checklist support.
- Commissioning: Shipped to Delhi NCR, 6-day on-site startup, operator training on pleat tension, hot-melt temp, SKU recipe switching, and daily cabinet cleaning.
4. Results
- Operators/shift: 7 → 2
- Reject rate: 4.0% → 0.7%
- Changeover: 24 min (Swift ↔ Baleno ↔ Creta ↔ Nexon)
- SKU coverage: 40+ Maruti / Hyundai / Tata / Mahindra sizes managed by recipes, not manual setup
- Pollution-grade SKUs: PM2.5 + activated carbon + anti-bacterial cabin filters added without re-engineering the line
- Client quote:“India is a high-SKU, price-sensitive, pollution-heavy market. Hengchao gave us 415 V / 50 Hz, Hindi on the screen, and charcoal media that doesn’t leak or delaminate. Our operators understood the machine on day one. That is why we chose them over cheaper quotes.”— Director, Indian Filter Manufacturer
5. Follow-up
After stable running, the client requested a quote for a second rotary pleater for commercial-vehicle and tractor cabin filters, and a PU-frame module for premium SUV / EV cabin projects (Creta, Seltos, XUV400, Nexon EV).
