Case Study: How We Solved the PU Foaming Bulge Issue and Reduced Production Costs by 15% for Refrigerator Giants

1. The Industry Challenge: The "Invisible" Defect in Appliance Manufacturing

In the polyurethane (PU) foaming process of refrigerator production, the fixing quality of condenser tubes is paramount. Even a minor adhesion failure can lead to significant structural defects.

Industry leaders like Midea and Haier have long struggled with a specific "dilemma" regarding traditional film-laminated aluminum foil tapes:

• The Adhesion Paradox: Traditional non-linear foil tapes use a release coating (anti-stick layer) that prevents the PU foam from bonding to the tape's back. This creates air pockets and "bulges" on the refrigerator shell, leading to high scrap rates.
• Climate Sensitivity: Traditional synthetic rubber adhesives are notorious for failing during seasonal temperature shifts, causing tape snapping or de-bonding, which leads to unplanned production downtime.
• The Cost Burden: High-performance adhesives often account for 20%-30% of the total tape cost, squeezing the profit margins of OEM factories.

2. Our Innovation: Proprietary "Adhesive-Compatible Release Agent" Technology

To bridge the gap between "easy unwinding" and "strong foam bonding," Shixin’s R&D team developed a breakthrough Adhesive-Compatible Release Agent.

Technical Core:

• Dual Compatibility: For the first time, we achieved seamless compatibility between Acrylic and Synthetic Rubber adhesives within the same production framework.
• Surface Energy Engineering: Our technology ensures the tape unwinds smoothly from the roll but provides a high-energy surface once applied, allowing the PU foam to create a dense mechanical interlocking structure with the foil.
• All-Weather Stability: By optimizing the polymer matrix, we eliminated the seasonal "brittleness" or "goo-bleeding" common in standard tapes.

3. Proven Results: From Lab Testing to Global Supply Chain

This is not just a laboratory concept; it is a field-proven solution currently powering some of the world’s largest appliance factories.

Real-World Performance Metrics:

• Midea Group: Successfully passed full-process testing across multiple plants. Today, Shixin supplies 90% of the demand for Midea’s Nansha Factory.
• Haier Appliances: Our samples have passed rigorous validation in Haier’s central labs and are now deployed in production bases across Qingdao, Wuhan, and Guizhou.
• The 15% Advantage: By switching to our optimized solution, clients have reported a 10% to 15% reduction in total procurement and maintenance costs.
• Yield Improvement: The elimination of the "foaming bulge" issue has significantly stabilized production during peak seasons.

4. Why Shixin is the Strategic Partner for Appliance OEMs

Beyond this specific innovation, Shixin offers the scale and reliability required by Tier-1 manufacturers:

• Massive Capacity: Operating 7 high-speed coating lines with a daily output of 200,000 rolls.
• Compliance & Safety: All materials are RoHS, REACH, and ISO9001 certified.
• Rapid Prototyping: We offer customized slitting (10mm - 1600mm) and bespoke adhesive formulations to meet specific factory conditions.

5. Optimize Your Production Today

Are you facing high rejection rates due to foaming issues? Or is your current tape failing during seasonal changes?

Request a Technical Consultation & Free Sample:

• Sample Kit: Professional-grade rolls for onsite foaming tests.
• TDS & MSDS: Full technical documentation for your engineering team.
• Expert Audit: Let our engineers help you optimize your tape application for maximum cost savings.