About sunny & Sandy

Hunan Sunny & Sandy Toy Manufacturing Co., Ltd. (Sunny & Sandy) was founded in 2015 as a high-tech enterprise integrating toy R&D, production, and sales. Headquartered in Hunan, the company operates multiple manufacturing bases and specializes in developing 3D plastic toys, food-grade toys, and anime IP-related products. With its independently developed multi-color, multi-material integrated injection molding process, Sunny & Sandy provides high-quality, innovative toys to consumers worldwide.

In September 2024, driven by its keen market insights and passion for Chinese animation culture, Sunny & Sandy secured the exclusive nationwide IP license for Ne Zha 2 3D plastic food toys. The product quickly became a sensation, with single-item sales surpassing 200 million RMB, establishing Sunny & Sandy as a leader in the Chinese-style toy industry.

During the 2025 Chinese New Year movie season, Ne Zha 2 dominated the big screen, raking in 14 billion RMB at the box office. While audiences were thrilled by Ne Zha’s fiery rebirth in Fire, another story of “rebirth” was unfolding in the brightly lit workshop of Sunny & Sandy in Xiangtan, Hunan, on the third day of the Chinese Lunar New Year.

When the Production Meets New Year Rush

Rewind to September 2024, Sunny & Sandy was officially authorized as the exclusive nationwide manufacturer of Ne Zha 2’s 3D plastic merchandise. This achievement came with a formidable challenge: the material library would be available in November, and within just three months, the company needed to complete product design, mold development, mass production, and delivery—a task comparable to compressing Ne Zha’s mythical “three-year gestation” into just half a year.

As Ne Zha 2 exceeded all box office expectations, demand for Ne Zha-themed toys skyrocketed, further pushing Sunny & Sandy to its limits.

During the peak production period of the Chinese Lunar New Year, Sunny & Sandy resumed operations ahead of schedule to meet overwhelming order demands. The stability and high efficiency of Haitian injection molding machines played a pivotal role in this process. With their continuous operation capability, these machines ensured on-time delivery, while their high level of automation significantly reduced manual labor, improving production efficiency and stability. This technological advantage enabled Sunny & Sandy to successfully race against time in its production line’s extreme sprint.

From the Big Screen to Millions of Homes

Assistant to Sunny & Sandy’s Chairman, Yang Zhenlin, vividly described the production process as reshaping Ne Zha’s body layer by layer. First, ABS material is melted at high temperatures and injected into molds to form the “skeleton”. Then, various colors and materials are added in layers, “fleshing out” Ne Zha, “dressing” him, and “styling” his hair. Through multi-layer injection molding, even the most intricate details of the character are flawlessly reproduced.

“Haitian injection molding machines offer high precision and automation, ensuring that every tiny detail is accurately replicated,” Yang explained. “From Ne Zha’s eyes and nose to the intricate textures of his clothing, every detail seems to come to life.”

By overcoming technical challenges in injection molding precision and material compatibility, Haitian injection molding machines facilitated the seamless execution of this multi-layer complex production. This ensured that every detail was meticulously restored, every component was perfectly assembled, and the production process was both highly efficient and of the highest quality.

The “Creators“ Behind the Production Line

As Ne Zha 2 shattered box office records with 14 billion RMB in revenue, Sunny & Sandy also made history, achieving 200 million RMB in single-item toy sales.

From the cinematic legend of Ne Zha 2 to high-quality Chinese-style collectible figures, this cross-industry collaboration between Haitian and Sunny & Sandy proved that Chinese manufacturing could do more than just bring cultural IPs to life, it can also reinforce them with cutting-edge technology. This partnership is a testament to how innovation in manufacturing is fueling the rise of Chinese animation, marking a new milestone in smart manufacturing.

Founded in June 2000, HICAP AIoT Group has grown over its 24-year journey into a leader in bottle cap packaging for China’s liquor industry. The company focuses on providing high-quality packaging solutions for renowned liquor brands. With six production bases across China, HICAP serves as a trusted partner to China’s most prestigious liquor enterprises.

HICAP Huai’an, established in March 2022, spans an area of about 40,000 square meters with a Phase 1 facility covering 27,000 square meters. Featuring fully enclosed dust-free workshops, state-of-the-art production equipment, intelligent logistics systems, and efficient information systems, it stands as a benchmark for smart packaging factories.

Recently, we had visited this cutting-edge facility and engaging in an in-depth discussion with Mr. Li Tao, Vice President of Operations at HICAP.

01 Collaboration – Tech & Trust

02 Performance – Quality & Efficiency

Mr. Li highlighted that Haitian’s injection molding solutions meet HICAP’s rigorous standards for high-quality cap production through stable performance, high efficiency, and precise processing capabilities. The machines deliver low failure rates during continuous operation, ensuring high production efficiency. This reliability reduces costs and enhances operational flexibility, saving valuable time and resources for HICAP.

Additionally, Haitian’s advanced technology and precise control systems ensure each liquor bottle cap meets stringent dimensional and shape requirements. This unwavering commitment to quality ensures the caps’ sealing integrity and aesthetic appeal, helping HICAP secure market share and customer trust in a highly competitive industry.

03 Service – Power of Partnership

04 Digitalization – Trends of industry

As the era of digitalization, HICAP and Haitian’s partnership is poised to seize new opportunities. HICAP aims to enhance the digital intelligence of its equipment, striving for seamless integration with its internal information systems. Haitian Smart Solutions is responding to this need, offering intelligent, automated one-stop solutions to help HICAP achieve greater breakthroughs in cap packaging.

Tech is the Future

Over the past decade, HlCAP Group and Haitian Plastics Machinery have shared a vision of excellencefueled by their pursuit of cutting-edge injection mold.ing technology and superior quality. Each technicacolaboration has driven advancements in both quality and innovation, meeting the market’s demand fopremium packaging products.

With its meticulous craftsmanship and unwaveringfocus on technology, HlCAP has solidified its positioras a leader in China’s liquor packaging industryMoving forward,we wil continue to deliver smartermore efficient, and reliable technological solutionsdriving innovation and transformation in the packag.ing industry. Together, we aim to usher in a new erafor packaging.

In childhood, every toy carries the laughter and dreams of children. Behind each carefully crafted toy lies skilled craftsmanship and advanced manufacturing technology. 

With the ongoing expansion of China’s toy market, which surpassed 150 billion yuan in 2023 and is projected to exceed 280 billion yuan by 2029, Zhafir has become an indispensable partner for the toy industry with its outstanding injection molding solutions.

01  Quality Toys Rooted in Precision Manufacturing

As beloved companions to children, toys must meet high standards of safety and durability, which are primary concerns for parents. High-quality plastic materials, such as ABS plastic, are often the top choice for producing premium building block toys. These materials provide excellent impact resistance and prioritize safety by minimizing sharp edges that could harm young players.

However, creating high-quality, safe, durable, and visually appealing building block toys requires meticulous manufacturing. The assembly parts must undergo rigorous quality control to ensure the perfect fit—neither too loose nor too tight. This level of precision relies on high-precision injection molding equipment and advanced manufacturing techniques.

02 Precision Empowered in Building Blocks

High-precision injection molding machines are the cornerstone of manufacturing quality building blocks. By optimizing injection parameters such as pressure, speed, and cooling time, these machines significantly improve the dimensional accuracy and surface finish of block components. These machines are especially advantageous for complex, mass-produced parts, offering fast production speed, high efficiency, advanced automation, a wide range of colors and styles, precise dimensions, and easy adaptability for new designs.

03 Zhafir All-Electric Solution for Toys

Guangdong Blue Sky Plastic Products Co., Ltd. (Blue Sky) was founded in 1988 and is a professional manufacturer engaged in the research and development of plastic household daily necessities, mold manufacturing, injection molding, and sales. The company covers an area of over 67,000 square meters, with modern workshops of more than 100,000 square meters, modern loading and unloading platforms, an ultra-large raw material storage warehouse, and a large group of high-precision injection molding machines, as well as an intelligent unmanned production workshop. The company is committed to technological innovation and brand strategy development. With strong production capabilities and rich industry experience, it has now become a leader in the domestic household daily necessities industry.

02 First Witness ofNew Energy Efficiency and Productivity

As a long-term partner of Haitian, Blue Sky has had full confidence in the quality and technological innovation of Haitian’s products over the years. Therefore, when Haitian launched its fifth-generation technology, Blue Sky was quick to embrace this new technology with a forward-looking vision, opening a new chapter of energy efficiency and productivity.

Now, let’s join Yang Moulu, Assistant to the CEO of Blue Sky, to see how Blue Sky is leveraging these machines to achieve a win-win in production efficiency and environmental benefits.

02 A New BenchmarkThe Fifth-Generation TechnologyLeading Green Benefits

Upon entering Blue Sky’s workshop, 122 Haitian injection molding machines were lined up, working intensely and orderly. Each injection molding machine, with its excellent performance, demonstrates Blue Sky’s relentless pursuit of product quality and production efficiency. Among them, the newly introduced Haitian JU fifth-generation injection molding machines stand out. Under the efficient operation of the JU fifth-generation machines, chairs are precisely formed, smoothly demolded, and produced like flowing water.

After a year of use and precise testing, Yang Moulu from Blue Sky told us, “For a chair weighing 1,300 grams, it used to take 66 seconds to produce with a third-generation machine, but the JU fifth-generation machine can achieve a production cycle of about45 seconds.” 

This reduction of 21 seconds significantly improves production efficiency, showcasing the fifth-generation injection molding machine’s precise control over time costs and extreme pursuit, bringing substantial benefits to Blue Sky.

Equally impressive is the excellent energy-saving performance of Haitian’s fifth-generation injection molding machines. With the same screw and clamping force tonnage, strict energy consumption comparison tests show that the fifth-generation machines are 24% more energy-efficient than the third-generation machines. This figure is not only a leap in technology but also a responsibility and contribution to the environment.

03 HT·XTEN DA New Era of Production

In addition to significant efficiency and energy-saving effects, the HT·XTEND equipped on the fifth-generation injection molding machines has also brought unprecedented convenience to Blue Sky. Blue Sky’s frontline technicians can easily capture production data through the extensive intelligent functions with HT·XTEND, enabling fine analysis and scientific optimization, which is crucial for further improving production efficiency and product quality. Not only does this align with the development trends of modern manufacturing, but it also lays a solid foundation for Blue Sky’s long-term development.

Moreover, the fifth-generation injection molding machines from Haitian have also won Blue Sky’s favor with their outstanding stability and dsurability. During long-term operation tests, these machines consistently maintained a high-efficiency and stable working state, providing strong support for Blue Sky’s continuous production.

As one of the first users of Haitian’s fifth-generationinjection molding machines, Blue Sky is activelydemonstrating its relentless pursuit of quality and in-novation. The collaboration has not only brought significant improvements in production efficiency andcost savings to Blue Sky but set a new benchmark forthe entire industry.

Today, Blue Sky has fullyimplemented the use of Hai.tian’s fifth-generation injection molding machinesand has shared its successful experience with theentire industry. Looking ahead, we hope that Haitianand Blue Sky will continue to collaborate, exploringmore possibilities and jointly writing a new greenchapter of sustainable development.

Founded in Shenzhen in 2005, Zhejiang Bicom Optics Co., Ltd. specializes in the precise manufacturing of optical components, focusing on high-quality optical products for the LED lighting, automotive lighting, and security industries. With a robust array of over 130 injection molding machines, BICOM’s annual output value has exceeded 300 million RMB. This success has earned them widespread recognition and cooperation from numerous internationally renowned automotive lighting manufacturers, including Marelli, Hella, and Valeo, continuously showcasing strong growth momentum and market competitiveness.

Recently, we had the privilege to visit BICOM and embark on a journey exploring optics with General Manager Zhou Yun.

1. Optical journey: Customized Solutions Lead Transformation

Since its inception in 2005, BICOM has focused on the design and manufacture of optical components, particularly in the fields of LED and automotive lighting. The manufacturing of optical components demands extremely high precision and stability from the equipment. Facing the market’s stringent requirements for high precision, high transparency, and weather resistance of optical products, BICOM began seeking more specialized solutions.

In 2015, leveraging its extensive technical expertise and profound understanding of optical products, Zhafir custom-designed a series of optical-specific machines for BICOM. These machines not only ensured the optical performance and quality of products like optical lenses but also demonstrated exceptional scalability and stability.

As a result, BICOM began extensively adopting Zhafir’s all-electric optical-specific machines to replace the previous general-purpose injection molding machines. Currently, Zhafir’s all-electric optical-specific machines account for more than half of the factory’s equipment, significantly enhancing production efficiency and product quality, thereby boosting market competitiveness.

2. Specialized Customization: Upgrades in Optical Manufacturing

With the rise of the new energy vehicle industry, the design of automotive light guides has become increasingly complex, demanding higher flexibility and adaptability from injection molding machines. Zhafir’s custom-designed optical-specific machines for BICOM have adeptly met the production needs of irregular molds and transparent optical products. Their specialized design and configuration have brought a qualitative leap to manufacturing.

The specialized machines offer not only ultra-large mold capacity but also flexible injection units that can select different screw capacities based on the actual weight of the products, achieving optimal process control. This is particularly important in the light guide industry.

Zhafir’s all-electric optical-specific machines have also undergone customized improvements to core components based on BICOM’s actual usage. For screws, an optical-grade screw was developed to effectively prevent quality issues such as product yellowing and black spots, meeting the high standards of transparency and quality required for optical products. For motors, a high-load design was adopted to address the overheating problem of traditional motors during long-term operation, ensuring the continuity and stability of the injection process. Additionally, this motor design provides strong support for producing thick-walled optical products.

Over the years, Zhafir’s customized services andtechnological innovations have perfectly aligned withBlCOM’s needs. Each upgrade reflects an unwaveringpursuit of optical performance, providing a solidfoundation for BlCOM’s technological leadership andmarket competitiveness in the optical componentmanufacturing field.

At the intersection of light and technology, the storyof Zhafir and BlcOM continues. In the future, we wilcontinue to work hand in hand, tirelessly striving fo)technologicalinnovation,advancing the manufacturing technology of optical components, and continuously exploring newapplications ofinjection moldingtechnology in optics. This collaboration aims to pro.vide new ideas and solutions for the development ofighting systems in new energy vehicles.

Chongqing Yufa Intelligent Technology Development Co., Ltd. (hereinafter referred to as „Yufa“), headquartered in Chongqing, is a company integrating R&D, design, production, sales, and service of plastic household products. Currently, it has four production bases in Chongqing Dazu, Qijiang, Shapingba, and Changsha, Hunan, covering a total area of about 200,000 square meters. With a complete production system, more than 300 fully automatic injection molding machines, and 1,500 employees, the household production line is highly automated and large-scale, making Yufa a leading enterprise in the plastic household products industry.

In Chongqing, a land of industrial activity on the banks of the Yangtze River, Yufa has grown from a small workshop to a plastic household products company with four production bases over 24 years.

Since its establishment in 2000, Yufa has always adhered to the philosophy of continuous improvement, constantly exploring higher-end and more refined production methods. In this process, Haitian, with its advanced equipment and comprehensive service system, has become an excellent partner for Yufa, providing full support to help Yufa create intelligent production workshops, significantly enhancing production efficiency and product quality.

Recently, we had the opportunity to visit Yufa’s headquarters in Chongqing and discuss with Chairman Cai the smart manufacturing upgrade and quality secrets of the household products industry.

Stepping into Yufa’s smart workshop feels like entering a factory of the future. Here, more than 300 Haitian injection molding machines are operating busily, precisely controlling every production process to ensure product quality stability and consistency. Rows of robots work uniformly and efficiently on every task, and the automated production lines achieve a high degree of scale and automation. Every detail reveals Yufa’s persistent pursuit of quality.

The cooperation between Yufa and Haitian began in 2004. „I am from Zhejiang, and I have heard of Haitian since I was young. Choosing Haitian makes me feel very assured,“ Chairman Cai recalled. For Yufa, choosing Haitian is not just selecting a brand, but also fully trusting its strong R&D strength, technical expertise, and continuous innovation drive.

After 20 years of collaboration, this sense of trust has only deepened over time. Haitian injection molding machines are not only durable and stable in performance but also flexible enough to meet various production needs. This allows Yufa to handle both large orders and customized products with ease, thus making Haitian machines an indispensable core force in daily production. The cooperation between Yufa and Haitian has also become increasingly close.

As the cooperation deepened and facing the increasing quality demands of the industry, Haitian tailored the HA/ara series for deep cavity household product solution for Yufa. This model, while inheriting all the advantages of traditional Haitian machines, further innovates by adopting high-efficiency plasticizing components, achieving a leap in plasticizing capabilities. Precise temperature control and optimized screw design significantly improve production efficiency and product molding quality. Moreover, a larger mold opening stroke meets the needs of special deep cavity product processes.

The innovation of specialized machines perfectly matches Yufa’s pursuit of high-end manufacturing and lean production. With its high efficiency, excellent cost-performance ratio, and outstanding stability, the specialized machine quickly became the main force on Yufa’s production line. The development of specialized machines is a reflection of Haitian’s strategy of „Technology to the Point“.

Meanwhile, the construction of smart workshops by Yufa and Haitian Smart Solutions is also a major achievement of their cooperation. From centralized material supply systems, AGV intelligent transfer vehicles, „Go Factory Pro“ MES systems to robots, a series of intelligent introductions have enabled Yufa’s production workshops to achieve high automation and informatization management. This not only reduces labor costs but also improves production accuracy and stability, achieving a significant leap in production efficiency.

Every investment here is transformed into tangible output. Chairman Cai expects, „We should be able to recoup the costs in three years.“

The story of Yufa and Haitian is a journey of trust, cooperation, and continuous innovation.In the futureHaitian will deepen R&D and innovation in thehousehold products industry, actively exploringnewer intelligent manufacturing models, helpingcustomers to further expand its market, and contrib.uting to the standardization and transformation ofthe industry.

As technology continues to upgrade and evolve, Haitian will also strive to develop more industry-specifidsolutions, focusing on the technical needs of different sectors, and working with customers from various industries to explore broader market.

Changzhou Nanyuan Plastic Co., Ltd., founded in 1991, covers an area of 48,000 square meters. It is a private enterprise specializing in the production and sales of plastic cap products, as well as the design and manufacture of plastic cap molds and blow mold barrels. Nanyuan serves multiple sectors including petrochemicals, food and beverages, and medical industries.

With its keen market insight and continuous innovation, Nanyuan Plastics has successfully set a benchmark in the plastic cap industry. Recently, we had the privilege to visit this industry-leading company to discuss the development trends of the plastic cap industry and engage in an in-depth exchange on cutting-edge injection molding technologies.

1. From Hydraulic to Electric

At this point, Nanyuan discovered Zhafir electric injection molding machines from 千赢国际官网首页入口网址是多少 . Nanyuan quickly favored Zhafir machines for their efficiency, stability, and cleanliness.

2. A Win-Win of Greenness & Products

Driven by the „dual carbon“ goals and domestic environmental policies, the packaging industry is trending towards thinner and lighter products. As product weight decreases, the requirements for injection molding machine stability and injection speed increase.

The stability and injection speed of Zhafir electric machines enable Nanyuan to easily meet these challenges. This results in lighter products, significant reductions in production cycle time, increased yield, reduced resource waste, and compliance with environmental regulations, achieving a win-win for both product upgrades and environmental protection.

3. Intelligent Upgrade & New Production

Additionally, Nanyuan has adopted the „Go Factory Pro“ intelligent operation system from Haitian Smart Solutions, integrating intelligence into every production stage. Through Haitian Smart Solutions‘ intelligent scheduling and real-time monitoring functions, Nanyuan can more accurately track production progress and product quality. This system ensures stable pressure and temperature during normal operation and allows for timely detection and resolution of production issues through data analysis. As a result, product stability and yield are effectively improved, bringing significant benefits to the company and raising product quality to a new level.

Over the years, Nanyuan Plastics has become aleader in the plastic cap manufacturing field, drivenby its persistent pursuit of quality and forward-looking technological vision. lts advanced productionmodel and excellent product quality have garneredwidespread acclaim within the industry.

Looking ahead, Haitian and Zhafir will continue toprovide Nanyuan with cutting-edge technical sup.port.Together,we are committed to technological in.novation and industrial upgrading, exploring moreintelligent and sustainable production models, anddriving the plastic cap manufacturing industry to newheights.

Citylong Technology Development Co. Ltd. , established in 1990, (hereinafter referred to as „Citylong“) has always focused on the home furnishing sector. Today, Citylong is a leading domestic enterprise combining research, development, production and sales in the home furnishing industry. Citylong has two main production bases in Tianjin and Xuzhou, and a global sales network covering various regions.

With the increasing demand for a higher quality of life, there are significant opportunities for storage products in the market, and China is expected to become one of the largest markets for storage and furnishing products in the world. Recently, we had the pleasure of having a conversation with Mr. Pan from Citylong, discussing the development of the storage products industry and exploring the current trends and demands in the home living sector.

1. Producing with precision: Craftsmanship to perfection

It is not an easy task to create products that are recognized by consumers enabling companies to enter a market. For now over 30 years, Citylong has been committed to the housewares industry. Behind its rise as an industry leader is a commitment to strict quality control and continuous product development. Through independent innovation, Citylong has driven the comprehensive introduction of whole-home storage solutions and achieved a leading position in the industry.

Entering Citylong’s production facility, the entire factory is equipped with fast-cycling Haitian and electrical Zhafir machines. Since the 1990s, Citylong has been a true supporter of Haitian machines.

Citylong has always been exploring new machines and technologies, continuously improving injection molding equipment and pushing the limits of quality. Mr. Pan told us, „Every time a new Haitian machine is introduced, we want to be the first company in the civil goods industry to use and test it.“ At present, the total number of Haitian machines at all production sites is over 300, and it can be said that the continuous investment and development of Haitian machines are proof that Citylong is working tirelessly to improve product quality.

2. Cost reduction and efficiency improvement: achieving industrial advantages

In recent years, competition in the industry has intensified. Cost has become a major issue that many companies cannot escape. Mr. Pan explains, „In the past two years, we have almost exclusively purchased fast-cycling or electric machines. In particular, the high-speed machines can fully meet our energy-saving requirements. Although the initial investment for electric machines is higher, they do offer significant advantages in terms of total cost accounting. The initial investment can be amortized within two or three years.

In discussing other reasons for choosing Haitian, Mr. Pan mentioned that Haitian’s after-sales service, customer communication and support are customer-oriented, which is a significant advantage over other manufacturers. This is a key factor backing up Citylong’s decision to choose Haitian.

3. Fast response: seizing new online growth opportunities

Currently, e-commerce platforms have become one of the key sales channels for the home storage market. In addition to the opportunities presented by the online market, there is also the challenge of improving the flexibility of the company’s supply chain. „Nowadays, customers are very demanding. When they place an order, they expect delivery within three to five days. Last year, we had a unique special order, a multi-million dollar order that required fast delivery. The customer searched with all domestic industrial companies, but none could meet their expectations. Thanks to our advanced equipment, we were able to accept and execute this order,“ said Mr. Pan. Haitian’s fast delivery of high-speed machinery gave Citylong the hardware support and strong drive it needed to meet even the most difficult challenges.

Group Photo

On its journey to quality, Citylong spares no effort and strives for perfection at every step. The high standard of product quality, advanced production facilities and the advantage of a fast supply chain have contributed to Citylong’s remarkable success in the Household industry. Haitian will continue to accompany Citylong in its pursuit to shape homes for its consumers with beautiful memories of a cultivated life.

Vietnam Kai Guang Plastics Co. was established in 2008, located in Singapore Industrial Zone No. 2, Binh Duong Province, Vietnam, covering an area of 40,000 square meters, specializing in the development and production of various kinds of lotion pumps, ROLL-ON, bead bottles and other daily chemical packaging. The company now has a dust-free and constant temperature plant of 12,000 square meters, equipped with 99 sets of injection molding machines, 20 sets of ball making equipment, and 3 fully automated assembly lines for lotion pumps, ensuring 100% product testing of the production line.

Along with the accelerated economic recovery of Vietnam, more and more enterprises grasp the opportunity and set up factories in Vietnam. Recently, we had the honor of visiting Vietnam Kai Guang Plastics Co., to discuss the new market opportunities in Vietnam.

Haitian：Why did you choose to invest and build a factory in Vietnam?

Kai Guang Plastics: First, Vietnam’s tax incentives are an important factor attracting us to invest and establish a presence. Second, we provide support to numerous multinational companies, such as Unilever, Johnson & Johnson, and others. They all have factories in Southeast Asia, so there are a lot of synergies to invest here. Third, Southeast Asia is a very broad market, with immeasurable economic potential and market size, we hope to obtain greater development here.

Haitian：Your first machine was a Haitian injection molding machine？

Kai Guang Plastics: Our first injection molding machine was not Haitian. At that time, when we first came to invest, we directly transferred the old machines from China to use. Our company’s predecessor is a Taiwan factory, so initially, we used machines from Taiwan. But as time goes by our machines have been gradually replaced by Haitian machines.

Haitian：How did you get to know about Haitian in Vietnam?

Kai Guang Plastics: Haitian Vietnam has made investments in land acquisition and factory construction in Vietnam almost concurrently with us. Moreover, our proximity as neighbors cultivates a strong and intimate bond between our organizations. There are many companies come to Vietnam to invest, but there are not many companies like Haitian that can provide quality assurance and efficient after-sales service. In as little as 5 minutes after a phone call, Haitian’s after-sales service personnel will arrive and help us in the „last mile“ of service. Haitian’s efficient after-sales service has become an important factor and stable anchor for our daily production, and injected more certainty for us to take root in Vietnam market.

Haitian：After years of use,what is your evaluation of our machines？

Kai Guang Plastics: We are very satisfied with Haitian. Especially noteworthy is Haitian’s profound understanding for local clients. Haitian has undertaken extensive localization explorations in the Vietnamese market, resulting in customized technological solutions and service experiences for us. One example: Haitian’s machine interface is available in Vietnamese, which our previous equipment supplier could not provide such a considerate service. In addition, Haitian’s machines are easy to work with the surrounding automation equipment, which can bring one-stop solutions.

Haitian：What is the current machine start-up rate?Is the production condition satisfactory?

Haitian：Do you have any outlook for the future?

Ein Kundenbesuch bei der Emperor Mouldings B.V. in Alphen aan den Rijn, Niederlande.

Die Brüder Maarten und Peter Keijzer, Köpfe der Emperor Mouldings B.V., verkörpern eine neue Generation von Spritzgießern: fokussiert, effizient und gelassen – mit einem neuen Verständnis der Work-Life-Balance. In der Zhafir Zeres Serie sehen sie beste Voraussetzungen, um Spritzgießprozesse maximal effizient zu gestalten und die Automatisierung der Produktion voranzutreiben.

Aufgewachsen im elterlichen Spritzgießbetrieb, war für Maarten Keijzer schon sehr früh klar, dass er mal eine Spritzgießerei betreiben will. Dass sein Vater den Betrieb dann verkaufte, erwies sich im Nachhinein als gute Entscheidung, da Maarten ganz zwangsläufig eine eigene Firma gründen und aufbauen musste. 2019 vollzog er diesen Schritt, zunächst allein, seit 2022 ist sein Bruder Peter komplett mit an Bord.

Beide hatten von Anfang an genaue Vorstellungen: „So lange wie möglich keine Angestellten, dafür die Produktion ans Maximum zu bringen, so weit, dass wir zu zweit noch alles bewältigen können.“ Hauptprodukte sind kleine Clips für die landwirtschaftliche Nutzung, Endabnehmer sind Treibhausbetreiber. Neben der Agrarindustrie beliefern sie noch den Commodity-Bereich und technische Teile. Unterm Strich konzentrieren sie sich ausschließlich auf kleine Schussgewichte in hohen Stückzahlen. Denn wichtig sind ihnen hocheffiziente Prozesse, „produktionsfreundliche“ Produkte und Automatisierung an den Stellen, wo es sich lohnt und der Work-Life-Balance dient. Maarten Keijzer: „Sicherlich erlebte ich viele Dinge im Betrieb meines Vaters, die ich anders machen wollte. Das Prinzip »Nur wer hart arbeitet, wird es zu etwas bringen« mag in der damaligen Zeit seine Berechtigung gehabt haben. Heute haben wir andere Möglichkeiten. Im Zeitalter der Digitalisierung und ihren Tools ist es leichter, effiziente und schlanke Prozesse zu gestalten.“ Die vor kurzem eingeführte automatisierte Folierung der Kartons sei dafür ein gutes Beispiel. „Dieser Robot spart uns viel wertvolle Zeit.“ Zurzeit denken sie über ein Automated Guided Vehicle nach, welches dann nachts die vollen Kartons aus den Magazinen nimmt und somit die Stückzahlen erhöht.

Leidenschaft für Technik: Maarten (li.) und Peter Keijzer mit einem Venus Modell aus Lego, dass sie eigens mit Robotik und Peripherie ergänzt haben

Über sinnvolles Wachstum und Skalierbarkeit

Seit ihrer Gründung 2019 ist die Emperor Mouldings B.V. stetig gewachsen, im Output, Turnover, im Set-up. „Ist die Nachfrage da, wäre es unsinnig, nicht zu wachsen“, sind sich die Keijzers einig. „Aber immer nur mit Maß und Ziel.“ Dennoch sei Wachstum nicht generell das große Ziel, vielmehr gehe es ihnen um die „sportliche Herausforderung“, maximal viele Produkte zu spritzen mit den vorhandenen Maschinen und ihrer 2-Mann-Power. „In unserer Fertigung haben acht Maschinen Platz. Das ist immer noch eine Größe, die wir zu zweit händeln können. Und sollte der Markt mehr erfordern, werden wir sehen, wie weit wir mit unserer Manpower gehen können.“

Wachstum in diesem, ihrem Sinne setze voraus, dass Prozesse maximal effizient optimiert sind. Dass Zykluszeiten maximal reduziert sind und der 24/6-Nonstop-Betrieb maximal reibungslos verläuft, bei einer klar fokussierten Produktgruppe: einfache Kleinteile in großen Stückzahlen.

Dementsprechend haben sie ihren Maschinenpark ausgerichtet und punktgenau ergänzt. Das Herz der Produktion bilden aktuell fünf elektrische Zeres Maschinen mit viermal 900 und einmal 1.200 kN Schließkraft (eine weitere ist bestellt). Alle laufen mit integrierter Steuerung (Success-Serie 7 und 11) von Sepro Robotics. Die Werkzeuge sind mit externen Hotrunner-Systemen von PSG ausgestattet, eine eigens programmierte Error-Stopp-Funktion greift bei zu hohen Temperaturen in der Dosiereinheit. Auch das garantiert ihnen bei Emperor Mouldings eine nahezu Null-Fehler-Produktion. O-Ton Maarten Keijzer: „Wir hatten 2022 bislang gerade mal 1 Karton Ausschuss.“

„The electric Zeres fits very well with our philosophy: technology to the point for production to the point. The price-performance ratio is also unbeatable in our eyes. Our first 90-tonne Zeres has already gone through more than 6 million cycles without a significant malfunction.“ Maarten Keijzer, Emperor Mouldings B.V.

Mit Performance gegen steigende Energiekosten

Während das junge Unternehmen noch relativ gut und entspannt durch die Pandemie gekommen ist, schlägt die Energiekrise umso gravierender in ihrem Kernmarkt der niederländischen Agrarindustrie zu Buche. Steigende Energiepreise werden vermutlich viele Treibhausbesitzer in die Knie zwingen, spätestens im kommenden Winter. „Unser Lager ist voll und der Markt erst einmal gesättigt. Das heißt, von unseren Maschinen laufen aktuell nur zwei von fünf. Grund dafür ist, dass die Agrarindustrie extrem unter den steigenden Energiepreisen leidet und viele Endkunden bereits angekündigt haben, dass sie ihre Gewächshäuser über den Winter zusperren.“ Die beiden Brüder nehmen die Situation dennoch gelassen: „Eine Krise ist auch immer eine Chance. Bislang hatten wir Vollauslastung, jetzt nutzen wir die ruhige Phase für Neukundenakquise, liegengebliebene interne Projekte oder freuen uns über mehr Familienzeit.“

Natürlich machen sich die steigenden Energiekosten auch im eigenen Spritzgießbetrieb bemerkbar, doch durch die stringente Entscheidung für elektrische Maschinen und dem geringen Schussgewicht der kleinen Teile hält sich ihr Energieverbrauch in Grenzen. Ohnehin optimieren sie ihre Spritzgießprozesse auf maximale Energieeinsparung, um ihren CO₂-Fussabdruck so klein wie möglich zu gestalten.

Vom mutmaßlich größten Clip-Produzenten in Europa

Abgesehen davon arbeiten sie immer wieder weiter an der kontinuierlichen Automatisierung der Produktion, Stichwort: Effizienzsteigerung. „Die elektrischen Maschinen sind uns eine enorme Hilfe, in dieser hohen Effizienz zu produzieren. Unser Vater hatte hydraulische Maschinen, die musste er noch mit einem gewissen Vorlauf hochfahren und warten bis die Öltemperatur passt, einige Zyklen Ausschuss aussortieren und so weiter. Unsere Zeres-Familie schalten wir Montagmorgen ein und erst Samstagnacht wieder aus. Maschinen und die Success-Reihe von Sepro passen ideal zusammen. Ab dem ersten Shot wird fehlerfrei produziert“, erläutert Maarten Keijzer.

Ein weiterer, wichtiger Baustein für höhere Effizienz sind seiner Meinung nach Material-optimierte Prozesse, darin sammelte er wertvolle Erfahrung in seinem vorherigen Job bei einem Materiallieferanten. „Unsere Einspritzeinheiten sind alle mit einer Verschlussdüse ausgestattet, sodass wir während der energieintensiven Plastifizierung die Parallelfunktionen maximal ausreizen können. Jede eingesparte Sekunde schlägt sich unmittelbar auf die Energiekosten nieder.“

Neben allem Engagement hinsichtlich Energieeinsparung und -effizienz arbeiten sie ebenso konsequent an ihrer produktionsseitigen Nachhaltigkeit. Von anfangs 100 % neuem Rohstoff zu Startup-Zeiten sind sie nunmehr bei nahezu 100 % recyceltem und kompostierbarem Material angelangt.

Auf die Frage nach konkreten Visionen oder Träumen für die nähere Zukunft, fällt die Antwort denn auch eher bodenständig aus: „Zwei Tage nicht in die Firma, trotzdem läuft alles weiter“ – das sei schon mal eine gute Vision. Aber natürlich sind sie sich den anstehenden Herausforderungen durchaus bewusst und wollen sich dem auch stellen. Und wer weiß, „vielleicht werden wir ja auch die kleinste Smart Factory in Europa.“

Infokasten

Produktionsprofil der Emperor Mouldings:

• Alle Zeres Maschinen laufen problemlos im 24/6-Modus;
• Alle Maschinen sind mit Automation ausgestattet;
• Tagsüber werden die Maschinen gewartet und ggf. Prozesse optimiert, nachts produzieren sie mannlos;
• Gefertigt werden ausschließlich kleine Teile mit hoher Stückzahl;
• Hauptprodukte sind Clips für Tomatensetzlinge im Treibhaus.