AI Waterless Processing

Tanning

• QC Points:

Consistent Penetration of Tanning Agents: Verify that the tanning agents, whether chrome, vegetable, or others, penetrate the leather uniformly. Inconsistent penetration can lead to uneven quality and performance of the leather.

Correct pH and Temperature: Ensure that the pH and temperature of the tanning solution are maintained within the specified range. Incorrect pH or temperature can affect the effectiveness of the tanning process and the final quality of the leather.

Uniformity in Tanning Effect: Inspect the leather for consistent color and texture. Uniform tanning results in a leather product that has a consistent appearance and feel, which is essential for high-quality output.

Measuring

• QC Points:

Thickness and Uniformity: Ensure the hide has consistent thickness across its surface after fleshing, splitting, and shaving.

Cleanliness and Defect Inspection: Check for residual flesh, fat, or tissue after fleshing.

Chemical Balance and Moisture Content: Test the hide for proper liming, tanning, and moisture levels using laboratory analysis or moisture meters.

Inspection & QC

• QC Points:

Defect Identification: Inspects raw hides, semi-processed, and finished leather for defects like scars, holes, inconsistent thickness, or grain damage.

Dimensional and Physical Checks: Measures dimensions (size, thickness, and weight) and physical properties (strength, elasticity, and softness) to confirm they align with customer requirements.

Documentation and Compliance: Maintains records of inspection results and ensures compliance with industry standards and customer-specific requirements.

R&D

• QC Points:

Product Testing and Validation: Conduct tests on raw materials, prototypes, and final products to ensure performance, durability, and compliance with industry standards.

Process Optimization: Analyze and refine manufacturing or production processes to maintain consistency and improve efficiency while reducing defects.

Data-Driven Improvements: Use collected data from experiments and quality checks to identify flaws, innovate, and enhance product quality before mass production.

Lab

• QC Points:

Raw Material Testing: Ensure the incoming hides and chemicals meet specified standards by analyzing moisture content, fat percentage, and chemical purity.

In-Process Monitoring: Check pH, chemical penetration, and uniformity during critical stages (e.g., liming, tanning) to maintain consistency and avoid defects.

Finished Product Evaluation: Test physical properties (e.g., tensile strength, thickness, softness) and aesthetic attributes (e.g., color, finish) to ensure compliance with customer and industry standards.

Spectrometer Color Matching

• QC Points:

Accurate Color Measurement: A spectrometer objectively measures the reflectance or transmittance of light from a material, providing precise data on its color profile. This ensures consistency by comparing colors against predefined standards.

Minimized Subjectivity: Unlike visual assessments that depend on lighting and individual perception, spectrometers offer consistent results irrespective of environmental conditions, enhancing reliability in quality control.

Enhanced Product Uniformity: By detecting even minor deviations from the target color, spectrometers help maintain uniformity across batches, reducing defects and ensuring compliance with customer specifications.

Auto Spray

• QC Points:

Consistent Coating Thickness: Regularly monitor and calibrate the spray system to ensure uniform application of finishing materials, preventing over-spray or under-spray that could cause uneven coloration or texture.

Overspray Management: Maintain proper spray settings and exhaust systems to minimize waste, avoid contamination, and ensure a clean workspace, contributing to the overall quality of the finish.

Periodic Testing and Adjustments: Perform routine checks on spray nozzles, pressure, and material viscosity, and conduct sample testing to confirm adherence to required standards for color, gloss, and feel.

Milling

• QC Points:

Uniform Movement: Ensure the milling drum operates at a consistent speed and rotation. This prevents uneven softening or grain damage during the tumbling process.

Moisture and Heat Monitoring: Maintain the correct humidity and temperature inside the drum to achieve desired softness and flexibility without over-drying or overheating the leather.

Duration Control: Set milling times based on leather type and thickness to avoid over-milling, which can cause texture loss or excessive wrinkles.

Toggling

• QC Points:

Uniform Stretching: Ensure the hides or skins are uniformly stretched and properly aligned during toggling to prevent uneven drying and distortion of the leather.

Defect Inspection: Continuously inspect the leather for surface defects such as wrinkles, cracks, or blemishes during the toggling process to maintain consistent quality.

Moisture Content Monitoring: Regularly check the moisture content to ensure it is within the desired range, as improper drying can affect the leather’s texture and durability.

Packing

• QC Points:

Final Inspection: Inspect each leather piece for any defects or inconsistencies before packing to ensure only quality products are shipped.

Damage Prevention: Ensure the leather is packed securely, preventing bending, creasing, or other damage during storage or transport.

Labeling and Documentation: Verify that each batch is correctly labeled and accompanied by proper documentation for traceability and customer reference.

Roto Press

• QC Points:

Pattern Uniformity: Inspect the uniformity and clarity of the embossed pattern or design, ensuring it is consistently applied across the leather.

Impression Quality: Check for any distortions, incomplete impressions, or texture issues that could affect the appearance or precision of the embossing.

Surface Integrity: Ensure the leather surface remains undamaged during the pressing process, without cracks, tears, or unwanted marks.

Roller Coater

• QC Points:

Consistent Application: Ensure an even and consistent application of the finishing coat across the entire surface of the leather.

Defect Check: Look for any drips, streaks, or variations in thickness that could affect the appearance or performance of the finish.

Surface Finish: Inspect for uniform gloss, matte, or texture based on the specified finish requirements, ensuring the desired look is achieved.

Buffing

• QC Points:

Uniform Buffing: Ensure the buffing process is uniform across the leather without damaging or thinning the grain surface.

Texture and Smoothness: Inspect for consistency in the texture and smoothness, ensuring an even finish throughout the hide.

Imperfection Removal: Check that any surface imperfections, defects, or blemishes have been effectively removed during the buffing process.

Vacuum

• QC Points:

Moisture Content: Monitor the moisture content to ensure the leather dries to the optimal level without over-drying or retaining excess moisture.

Shrinkage or Deformation: Check for any shrinkage or deformation of the leather during the drying process, ensuring it retains its shape.

Surface Integrity: Inspect the leather for any cracks, damage, or surface imperfections caused by the vacuum drying process.

Dyeing

• QC Points:

Dye Penetration: Confirm that the dye has penetrated the leather evenly, ensuring full absorption throughout the hide.

Color Consistency: Check for consistent color throughout the batch, avoiding streaks, spots, or patches of uneven dye.

Drying Process: Ensure the leather dries uniformly without any color variation, fading, or discoloration after drying.

Shaving

• QC Points:

Leather Thickness: Verify that the thickness of the leather is reduced to the required specification, ensuring it matches the target measurements.

Surface Quality: Ensure the leather surface remains smooth, without any cuts, gouges, or damage from the shaving process.

Thickness Uniformity: Measure the uniformity of the leather’s thickness across the entire hide to confirm consistent results after shaving.

Splitting

• QC Points:

Thickness Consistency:Measure thickness at multiple points to ensure uniformity within specified tolerances.

Even Splitting:Inspect edges for cleanliness and straightness, avoiding any uneven or ragged areas.

Grain Side Inspection:Check the grain side for defects, such as scars or discoloration, using good lighting for thoroughness.

Thickness Controls

• QC Points:

Uniformity in Thickness: Achieving consistent thickness across the entire hide ensures the leather meets customer specifications and is suitable for its intended application.

Avoiding Over-Processing: Excessive thinning can weaken the leather, affecting durability and tensile strength, while insufficient thinning may hinder flexibility.

Standardized Testing: Post-process quality checks ensure that the leather falls within acceptable thickness tolerances, preventing defects.

Sammying

• QC Points:

Moisture Content: Ensure the leather has a uniform and appropriate moisture level after sammying (usually around 55-65%). Excess moisture can lead to poor drying, while insufficient moisture may cause stiffness and cracking.

Surface Consistency: Inspect the leather for wrinkles, uneven textures, or mechanical damage caused by rollers or pressure plates. A smooth, consistent surface is essential for further processing.

Thickness Uniformity: Verify the leather thickness is even across the entire hide. Irregular thickness can lead to defects during finishing and issues with product quality.

Fleshing Operation

• QC Points:

Inspection of Raw Materials: Ensure hides or skins meet required quality standards, checking for defects like scars, holes, or uneven thickness.

Monitoring During Processing: Maintain consistent chemical and physical parameters (e.g., pH, temperature, time) during key stages like tanning, dyeing, and finishing.

Final Product Testing: Conduct physical tests (e.g., tensile strength, tear resistance, flexibility) and visual inspections for surface quality, color consistency, and finish.

CAD Model no. 1

Streamlined sophistication.

CAD Model no.2

Enhancing strategic synergies.

Old Factory:1998,Kanpur

New Factory:,Banther

Mollisa

• QC Points:

Softness: Verify that the leather softness meets the required specifications, achieving the desired feel without compromising durability.

Structural Integrity: Inspect for any signs of over-softening or weakening of the leather structure to maintain strength and quality.

Color and Finish: Ensure that the softening process does not alter the leather’s color or finish, keeping its appearance intact.