Shortly after industry news came that down-filling workshops of Youngor and Bosideng took on a completely new outlook, our journalist specially went to University Science & Technology Park of Changshu Southeast Development Zone and interviewed Qian Weibo, the President of Jiangsu Bealead, who described the research and development process of fully automatic weighing down-filling machine to the journalist.
Initially developed down-filling machine controlled weight of down with flow method. Although it increased down-filling speed, the users, after trying the machine, found it unable to satisfy their requirements in weight at all. Bealead R&D team resolutely gave up the technical plan, and started research and development anew. Through efforts of more than 3 months, automatic weighing down-filling machine took initial shape but was followed by series of problems. Interfered with by static electricity, down-filling machine additionally equipped with weighing module still couldn’t meet weighing precision standard of the users. “Edison conducted nearly 10,000 experiments in order to find appropriate material for filament”. Taking the great inventor as a model, Bealead R&D team encouraged the R&D Department to continually conduct tests and finally overcame weighing precision problem caused by static interference. However, direct contact between weighing connector and the balance body prevented weighing precision from meeting the error limit of 0.1g. Bealead R&D team tackled the technical difficulty day and night and finally developed non-contact weighing method for down-filling machine. From then on, Bealead fully automatic weighing down-filling machine has reached international leading level in weighing precision.
After increase of weighing precision, running speed of the machine is the most important problem faced by Bealead. Huang Xiaohua, a director and the General Manager of the Garment Industry Department of Bosideng Holding Group Co., Ltd., told the journalist the greatest advantage of automated equipment lied in enhancing both quality and productivity but Bealead down-filling machine didn’t meet their expectation during the trial stage. However, Bealead R&D team continually made technical breakthroughs. Down-filling speed of the machine is now twice or 3 times of traditional manual down filling, which has brought considerable economic benefits for Bosideng Group on the market featuring universal rise of workers’ wage.
Fully automatic weighing down-filling machine purporting to be environment protective and pollution-free failed to effectively improve environment during its initial stage. “Dust removal system used in conjunction with the machine has been developed as required by 361°”, a worker of Bealead told the journalist. Dust removal system can not only recycle down and reduce waste of raw material but also can efficiently improve environment of down-filling workshop, guarantee health of workers and improve overall image of the factory.
After software debugging is finished and zero drift problem of weighing module is solved, fully automatic weighing down-filling machine becomes basically mature.
Another problem continually troubled Bealead team before genuine maturity of the product. Most down garment fabrics are impervious fabrics for preventing down penetration. When down is pushed to down garment panels by air, the air cannot be smoothly discharged and down cannot be normally filled. That is to say, down often cannot be filled into panels. Bealead team tried to solve this problem by adding a device similar to bottle at the down outlet to prolong the time for air to push down. Unexpectedly, such bold trial proved to work. They added a bottle body outside the down outlet and down was surprisingly pushed into garment panels. Then Bealead R&D team repeatedly performed tests and finally determined the device to be 30 cm long. The length is adequate to ensure pressure-driven can push down into panels. Air went out after down entered garment panels. Although they cannot clearly explain the mechanic principle, the state after adding the “gun barrel” is what they need.
Similar inventions are numerous and witness trials conducted by Bealead team. What has supported the team in countless tests and improvements is the corporate product concept of pursuing constant improvement. “The down storage box could only store 3 kg of down but now can be filled with more than 8 kg of down”. Qian Weibo is satisfied with every current parameter of the product. “The more down-filling grids are, the lower deviation ratio is. The deviation ratio of an entire down garment can be controlled below 1 g.”
Since launching fully automatic weighing down-filling machine to the market in October 2012, Bealead has sold more than 600 down-filling machine series products. Many large garment manufacturers unanimously praise Bealead down-filling machines for high down-filling speed and stable quality. People of Bealead are very proud of that. “Bealead is not the only manufacturer of like products but clothing factories have finally selected down-filling machines of Bealead after repeatedly comparing performance of the products in use.”
Always valuing research and development, Bealead has never stopped launching new products. It is known that upgraded version of Bealead fully automatic weighing down-filling machine will be launched to the market later in the second half of this year. The new machine will not only be changed in appearance but also will be improved in operating convenience, down-filling speed and precision. Internet technology is adopted for the new down-filling machine so that factory managers are able to learn about use of each machine at any time as well as output and down loss rate of each day through computer or mobile phone. Technical personnel of Bealead can help users adjust equipment parameters remotely, which significantly reduces service response time and increases efficiency.
Up to now, Bealead has applied for over 20 patents for its fully automatic weighing down-filling machine. Facing the disorderly garment equipment market, Bealead says it dare not treat intellectual property right protection and will resort to law to protect its rights and interests at any time. Besides, Bealead products have obvious advantages in comparison with foreign like products. As the writer knows, Britain has produced the same type of down-filling equipment, which runs at low speed because down is pulled mechanically. Japanese down-filling equipment is highly mechanized but down-filling precision is low because the down-filling tube has a large diameter. Therefore, it is only fit for making household textile products.
Jiangsu Bealead Software Co., Ltd. was established in 2007 and focused on providing garment enterprises with computer software service for realizing modernized management at that time. Established in 2011, Changshu Bealead Automatic Machine Co., Ltd. is engaged in development and manufacture of mechanical products. Also established in 2011, Bealead E-commerce Co., Ltd. relies on high-quality garment production resources in Changshu and is dedicated to build “specialized down operator”. The Company officially launched down-filling machine to the market in 2012. Firmly believing science will change garment, people of Bealead say they will make business of Bealead evergreen by virtue of the evergreen garment industry.
As a specialized equipment provider, Bealead has developed many customers, such as Bosideng, Youngor, UNIQLO, Nike, Li-Ning, Anta, 361° and other domestic famous brands. “In recent days, the Sales Department of the Company receives 8 to 10 phone calls every day. These manufacturers paying attention to fully automatic weighing down-filling machine are from different areas across China.” Qian Weibo often emphasizes to the employees how to properly track visiting customers instead of how to sell Bealead products. “The reason is that product is the best salesperson of Bealead.” Having majored in modern marketing management and practiced in business circle for decades, Qian Weibo has developed his unique sales techniques.
Bealead will uphold the concept “automation creates value” in making products. At present, Bealead team still values development of new products. They hope the combination between mechanical manufacture with computer technology will enable garment equipment to replace human labor to the greatest extent.