Поставщик салонных фильтров HC-Air
The Saudi client supplies the Kingdom’s fast-growing automotive aftermarket and fleet/service-network channels in Riyadh, Jeddah, and Dammam. In Saudi Arabia, high temperatures, frequent dust, and sand-laden air make cabin filtration a comfort and HVAC-protection issue, not a optional extra. Their buyers increasingly ask for activated carbon and multi-layer cabin filters that can hold more dust and remove odors from traffic and desert air.
The client’s old semi-automatic cell had clear limits:
- 7–8 operators per shift
2. Solution & FAT
Hengchao delivered a green-and-white modular cabin filter line with Gulf adaptation:
- Electrical: 380 V 3Φ / 60 Hz motors + VFD tuning, wide-input control supply, voltage stabilizer recommendation, surge protection, IP65 control cabinet option for dusty sites
- HMI: Bilingual Arabic + English interface, recipe storage by vehicle model
- Media range: non-woven, synthetic, HEPA/nanofiber, 2–3 layer activated carbon
- Stations: servo blade 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 Saudi technical manager 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: 600 pcs on charcoal + HEPA blend simulating Gulf dust/pollen/odor load; Cpk shared for edge offset and glue width.
- FAT: Verified 300×250 mm Land Cruiser cabin filter at 90%+ OEE. Arabic HMI, 60 Hz motor parameters, 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 + Arabic glossary, PLC backup, spare-parts kit, SABER/SASO documentation support for finished filters.
- Commissioning: Shipped to Riyadh, 6-day on-site startup, operator training on pleat tension, hot-melt temp, mold change, and daily cabinet cleaning in dusty environment.
4. Results
- Operators/shift: 7 → 2
- Reject rate: 4.0% → 0.7%
- Changeover: 26 min (Camry ↔ Land Cruiser ↔ Hilux)
- Медиа: charcoal/HEPA SKUs added without re-engineering the line
- Dust performance: sealed edge reduced air bypass; cabin packs passed client’s leak-check jig consistently
- Client quote:“Hengchao did not send a 50 Hz Chinese machine and hope it works. They built for Saudi conditions — 60 Hz, Arabic screen, glue stable on charcoal, cabinet ready for dust. That is why we signed.”— Factory Director, Riyadh Client
5. Follow-up
After stable running, the client ordered a second rotary pleater for truck/SUV sizes and requested a quote for PU-frame cabin filters for luxury SUV and EV cabin projects in the GCC.
