Application Case: Plastic Film
Project Background
At the production base of a leading film enterprise specializing in packaging plastics, the factory utilizes PP polypropylene as its core raw material to manufacture films via a biaxial stretching process, with a daily feeding requirement of approximately 150 tons. Previously reliant on three workers rotating shifts for manual feeding, the operation faced excessive labor intensity and severe mismatches between seasonal production fluctuations and staffing levels—experiencing labor shortages during peak demand and recruitment difficulties during off-seasons.
The primary challenge emerged from the massive throughput requirement: standard bag-opening robots operate at only around 4 tons/hour, meaning two units would be needed to meet daily capacity, yet the tight factory layout made installing a second machine impossible, necessitating a high-speed solution.
To resolve this, the project implemented Hanchine's standard Pro Series bag-opening robots, which feature ultra-high-speed feeding capabilities of up to 8 tons/hour. This allowed the system to easily satisfy the strict capacity requirements of the downstream production line, effectively solving labor instability caused by demand fluctuations, replacing high-intensity manual work with automation, and ensuring efficient, stable operations that align perfectly with the high-speed continuity demanded by film manufacturing.
Challenges
Extreme Capacity Demand
A daily feeding volume of 150 tons far exceeds the ~4 tons/hour capability of standard robots, where conventional solutions would require two units.
Limited Floor Space
The compact factory layout could not accommodate the footprint required for dual machines, creating an urgent need for a single-unit high-speed solution.
Labor Management Issues
Severe mismatches between seasonal peaks/troughs and workforce availability led to labor shortages during high demand and difficulties in recruiting temporary staff, compounded by high-intensity manual labor.
Solution
Core Equipment
Deployment of Hanchine's Pro Series Bag-Opening Robots.
Performance Advantage
Ultra-high-speed feeding capability reaching 8 tons/hour.
Spatial Efficiency
A single machine replaced the traditional dual-unit setup, resolving the constraint of the tight workshop layout.
Application Value
Capacity Assurance
Easily meets the 150-ton daily feeding requirement, ensuring uninterrupted supply to downstream lines.
Cost Reduction & Efficiency
Eliminates issues related to labor intensity, recruitment difficulties, and staffing imbalances, achieving headcount reduction while maintaining output.
Process Optimization
Replaces manual labor with high-speed automation, significantly enhancing the continuity and stability of the film production line.
rOI
Doubled Efficiency
Robotic high‑speed bag opening with stable cycle time and significant capacity increase.
Labor Reduction
Cuts 2–3 operators per line, reducing labor costs by ~60%.
Near‑Zero Residuals
High‑precision feeding minimizes leftover material and maximizes raw material utilization.