产品加工流程Production Process

 

内部生产过程In House Production Process

研发,乳胶配制,吸尘,针轧,胶化,硫化,铸型,切割,冲压和加工。整个生产过程都是在可可产业内部完成。

Research and development, latex compounding, vacuuming, needling, rubberising, vulcanising, moulding, cutting, punching and finishing.The entire production process at Coco Industry is completed in-house.
 

乳胶配制Latex compounding

从日本引进的技术,然后在内部严谨研发配制。Fibrelux®的核心秘密是使用100%纯天然乳胶,对硫化剂的使用达到最低要求,因此提高了乳胶的耐用性和天然弹性。针对特定应用,如涉及袋装弹簧或缓解压力的防褥疮床垫,使用特制的乳胶化合物。

The Japanese inherited then in-house developed latex formulations are compounded with great care. The use of 100% pure natural latex requiring a minimum of vulcanizing agents is the secret of the durability and natural elasticity Fibrelux® core. For specific applications, such as covering pocket springs or pressure-relieving anti-decubitus mattresses, special compounds are prepared.
 

吸尘Vacuuming

拆包后的纤维,在进入针轧或喷胶的进程前先通过吸尘,清理超过90%的短纤维和纤维粉尘的过程。这过程只容许长纤维进入到最终产品,以确保我们的质量。

After unpacking the fibres, all fibres will then go through a vacuuming process before entering needling or rubberising process to clean up more than 90% of short fibres and fibre dusts. This is to ensure our quality by only allowing long fibres to be process into final products.
 

针轧Needling

纤维的针轧过程是一个特殊的技术,通常背面采用麻布或塑料为后援以连接纤维在一起。我们选择采用喷一层薄薄的乳胶液,应用于增强纤维之间连接力。

In the needling process the fibres are linked together by a special technique, normally onto a hessian or PP backing. A thin layer of latex may also be applied for enhanced binding of the fibres. Needled coir are produced in rolls and sheets.


 

胶化Rubberising

曲纤维在喷涂乳胶生产过程中被塑造成一个如羊毛绒的分布薄片。曲纤维和乳胶结合在高温烘焙过程下,然后硫化成弹性椰纤维(椰子纤维)片。在针轧装置类似,我们的工厂具备自己的胶化装置。

The spun natural fibres are shaped into a fleece and sprayed with latex as part of the production process. The latex binds the curled fibres which are then pressed and vulcanised in several layers into resilient coir fibre (coconut fibre) sheets. As in the case of the needling process, our factory has our own rubberising plant.


 

铸型Moulding

胶化和针轧的椰子纤维(椰子纤维)压在模具中,然后用高温(> 100度摄氏)硫化。广泛应用于家具的床垫,坐垫和扶手。模具和规格均根据客户的需求在我们的工厂内部制造为了控制质量的一致性。

The freshly rubberised and needled coir fibres (coconut fibre) sheets are pressed in moulds and then vulcanized with high heat (>100 Degree Celcius). Widely used applications are mattresses, seat cushions and armrests for furniture. The moulds and specification are manufactured in-house according to the customerˇs specification.
 

床垫外套绗缝及缝纫Cover Quilting & Sewing

床垫设计其中一个重要的程序是有一个外观吸引力的床垫外观。在巨型多针绗缝机的帮助下,绗缝出外观精美的床垫外套。顶部,底部,使用耐用边带缝纫,由边带操作员手工送入缝纫机,因为床垫的移动。边带缝纫在很大程度上取决于操作员的技能,以制造专业标准的终端产品。

The core mattress is given an attractive exterior by decorative mattress cover. The cover is manufactured with the help of giant quilting machines having a multitude of needles that stitch the cover to a layer of backing material. The Tape edge operators manually feed the top, bottom, and side panels and a heavy duty binding tape into the sewing machine as it moves around the mattress. It highly depends on the skill of the operators to feed just the right amount of each material into the machine in order to get the end product of a professional standard.