Project Overview
| Item | Details |
|---|---|
| Client | Global Logistics & Shipping Company |
| Country | Russia |
| Industry | Container Transport Protection |
| Product | Dunnage Air Bags for Cargo Securing |
| Project Goal | Lower Inner Bag Cost, Reduce Labor, Multi-Size Compatibility |
Client Challenges
The Russian logistics company needed to optimize dunnage air bag production by reducing manufacturing costs, improving automation, and ensuring reliable cargo protection during transportation.
High Inner Bag Cost
Conventional machines require PA/PE co-extruded film, which costs nearly twice as much as pure PE film. At high production volumes, the material premium significantly increases overall manufacturing costs.
Material Waste
Older production equipment generated 2–5% scrap due to sealing failures and edge trimming, directly reducing production margins.
Rising Labor Cost
Semi-automatic bagging processes required multiple workers per shift, while labor costs continued to increase.
Multi-Size Production
Different container sizes require different dunnage bag dimensions. Traditional machines require slow and labor-intensive mold changes when switching between sizes.
Bag Breakage
Weak seals could cause bags to burst during transportation, resulting in cargo damage, insurance claims, and customer complaints.
Our Solution
HAOSEN provided an intelligent dunnage air bag production solution focused on material cost reduction, automation improvement, and flexible production capability.
Equipment Highlights
| Feature | Specification |
|---|---|
| UPT Pulse Sealing | Middle-frequency pulse sealing technology supports pure PE film instead of only PA/PE co-extrusion, reducing inner film cost. Zero sealing breakage and zero material waste. |
| Automatic Bagging & Sewing | Fully automatic inner-to-outer bag assembly reduces labor requirements by 70% compared with semi-automatic processes. |
| Multi-Size Compatibility | One machine supports multiple bag dimensions with fast parameter changeover through a touchscreen system without mold replacement. |
| AI Control & Remote Monitoring | PLC-connected system provides real-time production data, AI voice alarms, and remote diagnostics from HAOSEN engineers. |
Core Technical Parameters
| Parameter | Value |
|---|---|
| Applicable Materials | Pure PE, PA/PE Co-Extrusion, Composite Film |
| Film Thickness | 20–1000 μm |
| Max Unwinding Width | 1600mm |
| Mechanical Speed | 15–22 Cuts/Min |
Key Results
| Metric | Result |
|---|---|
| Inner Bag Cost Reduction | 20% |
| Labor Saving | 70% (Fully Automatic Bagging) |
| Bag Breakage Rate | 0% |
| Material Waste | 0% |
| Energy Saving | 66% Compared with Conventional Models |
| Multi-Size Capability | One Machine Supports All Container Sizes |
Process Showcase
- Production line: intelligent dunnage air bag making machine.
- Production launch: machine operation and customer FAT inspection.
- Finished product: dunnage air bag inflation test.
- Application: dunnage bags securing cargo inside containers.
Client Testimonial
"The UPT sealing technology was the deciding factor — using pure PE instead of PA/PE cut our inner bag cost by 20 percent overnight. Zero breakage in transit means zero cargo damage claims from our customers. The automatic bagging station cut our labor requirement by 70 percent. We have not had a single quality complaint since commissioning."
— Purchasing Director, International Logistics Company, Russia
