Integrated 200 PCS/MIN High-Speed Mask Production Line | Fully Automatic 1-to-2 System with AI-Vision Quality Inspection & PLC Automation

Integrated 200 PCS/MIN High-Speed Mask Production Line | Fully Automatic 1-to-2 System with AI-Vision Quality Inspection & PLC Automation

Product Description

Our latest Integrated Mask Production System represents the pinnacle of automated hygiene equipment. By synchronizing a high-speed mother machine with dual child-welding units via advanced PLC logic, this end-to-end solution delivers a stabilized output of 150–200 pieces per minute. This system is specifically designed for manufacturers transitioning from manual sub-mask equipment to a fully centralized, smart manufacturing workflow.

System Advantages & Technical Innovations

1. Centralized PLC Synchronization: The mother machine intelligently allocates mask bodies to two ear-loop welding units via a Human-Machine Interface (HMI) touch screen. This ensuring perfectly balanced distribution and maximum hardware utilization.

2. Integrated AI-Vision Quality Detection: This upgraded system features an industrial-grade AI camera module. It performs real-time visual inspection to detect and auto-reject defective masks (welding errors, strap misplacement, or material flaws), maintaining a zero-compromise quality standard at 200 PPM.

3. Adaptive Material Engineering: Optimized to process 1–5 layers of non-woven and melt-blown fabrics. The system allows for precise adjustment of mask dimensions and folding locations to meet various international filtration standards.

4. Corrosion-Resistant Aluminum Structure: The entire chassis is constructed from high-grade Aluminum Alloy, providing a rust-proof, compact footprint (4400mm x 4000mm) that is ideal for medical-grade cleanroom environments.

5. High Reliability & Low Failure Rate: Combining photoelectric detection with computer-programmed logic, the system monitors every step of the workflow, significantly reducing downtime compared to traditional standalone units.

Technical Specifications

After-Sales & Deployment Support

• Custom Configuration: We provide tailored setups for specific mask body sizes and ear-loop orientations (standard exterior welding).
• Power Grid Customization: Electrical systems are configured to match your local grid (US/EU/Asia) to ensure immediate plug-and-play functionality.
• Remote Technical Diagnostics: All PLC-controlled lines include 24/7 remote support to assist with parameter optimization.
• Export-Ready Packaging: Machines are packed in vacuum-sealed PE film and reinforced wooden crates for safe international shipping.​

Project Planning & Technical FAQ

Q1: How does the 200 PCS/MIN speed affect the machine’s long-term stability?

A: To ensure stability at high speeds, we have upgraded the chassis to a reinforced 6061 Aluminum Alloy structure and replaced standard motors with a multi-axis servo drive system. Each line undergoes a 72-hour continuous high-speed stress test before shipment to ensure mechanical synchronization and heat dissipation are optimized for 24/7 operation.

Q2: What are the specific advantages of the integrated AI Vision Inspection?

A: At 200 masks per minute, manual inspection is impossible. Our AI system uses high-speed industrial cameras to detect defects in real-time, including ear-loop welding strength, nose-wire positioning, and surface contamination. This reduces your reject rate to below 0.8% and saves the cost of 1-2 manual QC staff.

Q3: Can the machine be customized for the US or European power grid?

A: Yes. We provide localized electrical configurations. For the North American market, we offer AC480V/AC240V 60Hz setups; for Europe, we provide AC380V 50Hz. The PLC interface is fully translated into English, and all pneumatic components use international brands (like SMC/Airtac) for easy local maintenance.

Q4: What is the expected ROI (Return on Investment) for this high-speed line?

A: By increasing output from 120 PPM to 200 PPM, this system produces an additional 48,000 masks per 10-hour shift. Combined with the labor savings from the 1-to-2 automated integration and AI inspection, most clients report an equipment payback period that is 35-40% shorter than standard models.

Q5: How do you handle after-sales support for such a complex automated system?

A: We provide a 1-year essential spare parts kit and 24/7 remote video technical support. The machine’s PLC supports remote diagnostics, allowing our engineers to assist with parameter tuning via video call. If on-site assistance is required, we can dispatch engineers for installation and staff training worldwide.

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Dongguan Sheng Chuan Machinery Factory

Contact Person: Rocky

Email: shengchuan_machinery@outlook.com

Mobile / WhatsApp / WeChat: +86 19820010917

Tel: +86 19820010917/+86 13728175682
Address: Daojiao Town, Dongguan City, Guangdong, China