Core Value: Precision Problem-Solving + Integrated Hardware-Software-Service Delivery = Quantifiable Results
1. Deep Diagnosis: 3D Operational Profiling
- On-Site/Remote Assessment : Expert teams capture critical data:
- Plant layout (single/multi-level), equipment specs (mixers/openers), daily capacity (e.g., 5,000 semi-steel tires), staffing.
- Raw material types (NR, carbon black, etc.) & logistics flow.
- Digital Twin Simulation : Predict bottlenecks (e.g., warehouse-production line distance inefficiencies) using proprietary simulation platform.
2. Tailored Solution: Integrated Hardware + Software + Service
Modular design based on MachTech's core systems:
| Module | Key Features | Customization Highlights |
| Smart Batching | ±0.1g accuracy, dust containment | - Carbon black: Dense-phase conveying (anti-clogging tech)
- Liquids: Pump + pipeline heating (anti-coagulation)
- 200+ recipe management
|
| Low-Temp Mixing | 25% energy savings, superior uniformity | Optimized rotor speed for tread rubber -> enhanced wear resistance |
| MES Platform | Full traceability, OEE monitoring | Real-time curing data + QR-based lifecycle tracking |
| VOCs Treatment | Base: ≤30mg/m³ (Activated carbon + UV) | EU upgrade: RTO (95% thermal efficiency, ≤15mg/m³) + CE support |
| Smart Warehouse/AGV | 4-way shuttle + WMS | Custom racks (500kg/layer), 40% faster throughput |
3. Agile Implementation: Phased Delivery
- Prefabrication : 30% faster install (core modules pre-built in Tianjin).
- Adaptive Installation : "Ground + Mezzanine" structures for low ceilings; laser-AGV cross-floor logistics.
- Seamless Integration : Proprietary protocols connect new/legacy equipment (e.g., vulcanizers).
- Certification Support : Local compliance & TSE/ECE documentation.
4. Challenge-Driven Innovation
| Challenge | Breakthrough Solution | Result |
4m column spacing (SE Asia plant) | - Foldable 4-way shuttle (3.5m aisle)
- Overhead conveyor for vertical material flow
| Space optimization + full automation |
EU IED Compliance (≤20mg/m³ VOCs) | - RTO add-on (≤15mg/m³)
- SGS pre-testing + real-time monitoring
| On-time CE certification |
| Legacy mixer data isolation | - Non-invasive sensors + edge computing (OPC protocol)
- Scan-to-associate manual entries
| Unified MES data ecosystem |
5. Case Study: Overseas Tire Plant Transformation
Client Profile
Passenger tire maker facing:
① 30% defect rate (batching errors)
② Dust/VOCs non-compliance
③ 15-day delivery cycle (lost EU contracts)
Solution
- Diagnose : Single-story workshop (6m height), 300m manual material transfer, 3 mixers (2 legacy).
- Design : Integrated batching -> mixing -> AGV logistics -> emission control + MES/ERP sync.
- Execution :
- Custom compact AGVs (1.2m turn radius) for narrow aisles.
- Legacy mixer retrofit with 4G edge gateways.
- 40-day launch (prefab + parallel construction vs. 90-day industry avg).
Results
| Metric | Before -> After | Impact |
| Batching accuracy | ±5% -> ±0.1% | ECE R117 certification |
| Order-to-delivery | 15 days -> 7 days | Regained 2 EU clients |
| Operational cost | -- | €1.2M/year saved (40% labor reduction) |
| Emissions | Dust: 80->12mg/m³; VOCs: ≤15mg/m³ | "Green Factory" certified |
Why MachTech?
- 26+ Years Expertise : Industrial IoT pioneer (est. 1996), National High-Tech Enterprise.
- End-to-End Capability : R&D -> manufacturing -> deployment (Tianjin/Zhuozhou bases + 5 China offices).
- Proven Scale : 506+ global clients; 1,470+ batching systems; 77+ MES deployments.
- Market Leadership : >75% China share in rubber/engineering plastics; key supplier for China-Laos/Yawan Railways.
- Innovation Backbone : 45 patents, 32 software copyrights, ISO 9001/14001, SGS-CE.
- Global Reach : Exports to 20+ countries (EU, ASEAN, MENA).