For jeans companies, cost control of the spray horse chestnut process is directly related to product profits and market competitiveness. For a long time, the high cost problem of traditional manual spraying of horse chestnut has been like a "giant rock" pressing on the shoulders of enterprises. The arrival of a new generation of non programming spray painting robots is using disruptive power to trigger a cost revolution in jeans spraying, allowing enterprises to bid farewell to the dilemma of "high consumption and low efficiency".

Labor cost: from "heavy investment" to "light operation"

The traditional spraying of horse chestnut is a typical "labor-intensive" process, which requires a large number of skilled workers to support a production line. Skilled workers generally earn a monthly salary of 8000-10000 yuan and have a training period of 1-2 years - newcomers need to start learning basic spray gun control. During this period, fabric loss and paint waste caused by operational errors are additional costs. What's even more tricky is the prominent problem of "recruitment difficulties" in the industry. During peak seasons, companies have to pay extra bonuses to compete for workers, resulting in high labor costs.

Programming free spraying robots have completely reversed this situation. Its "zero programming" operation mode allows ordinary workers to take up their posts after one day of training, without the need for high salaries to compete for skilled workers; The originally 20 person spray horse and willow workshop now only requires 2 people to monitor the operation of equipment, directly reducing labor costs by 70%. The person in charge of a denim factory in Zhongshan, Guangdong calculated that after introducing three robots, the monthly labor expenditure decreased from 200000 yuan to 60000 yuan, saving 1.68 million yuan in one year, which is equivalent to "half a year's return on investment" in equipment.

Material cost: from 'serious waste' to 'precise and controllable'

Paint waste is another major cost pain point for traditional spray painting. When manually spraying, workers control the amount based on experience. Either too much coating leads to accumulation and fabric damage, or insufficient coating results in exposed substrate. The utilization rate of coating is only 60%, and the waste rate is as high as 30%. Based on the monthly consumption of 3 tons of potassium permanganate solution (8000 yuan per ton) by medium-sized factories, the monthly waste of paint alone exceeds 7200 yuan, which is nearly 90000 yuan per year.

The "closed-loop coating control system" of the robot perfectly solves this problem. The system has a built-in database of more than 20 types of denim fabrics, which automatically matches the fabric material and thickness before spraying, and accurately adjusts the coating flow rate (minimum unit: 0.1ml/min) and spraying pressure. For example, when processing thick denim fabric, the flow rate is automatically increased to ensure uniform coloring; Faced with lightweight elastic fabric, reduce usage to avoid penetration. Data shows that robots have increased the utilization rate of coatings to over 90%, saving 1.2 tons of coatings per month, equivalent to nearly 10000 yuan in cost. This can save enterprises 120000 yuan in material expenses in one year.