A prominent motor manufacturing enterprise with a 30-year history faced critical challenges with its aging Vacuum Pressure Impregnation (VPI) equipment. The existing systems suffered from high energy consumption, heavy reliance on manual labor, and a complete lack of data traceability. Amidst intensifying market competition and stringent environmental inspections, the client urgently needed to upgrade two production lines with a rapid, non-stop transformation that would not disrupt ongoing operations.
The Solution: Modular Replacement + Smart Factory Integration
Our team proposed a "Modular Retrofit Strategy": retaining the robust structural framework while upgrading core components and completely reconstructing the software architecture.
Core Component Upgrade: In just 48 hours, we dismantled the old vacuum pump groups and heating systems, replacing them with our high-efficiency variable-frequency vacuum units and infrared radiation heating modules. This swap immediately reduced energy consumption by 35%.
Fully Automated Control System: We deployed a next-generation PLC + SCADA system, achieving full automation across the entire process—from preheating, vacuuming, and impregnation to pressurization and curing. This reduced manual intervention by 70%.
Digital Interconnectivity: By integrating interfaces with the client’s MES and ERP systems, we enabled automatic download of process recipes, automated generation of production reports, and real-time cloud uploading of quality data. The plant has truly stepped into the era of a "Transparent Factory."
Environmental Compliance: We installed integrated activated carbon adsorption and desorption units, stabilizing VOC emissions at below 30 mg/m³—far exceeding local environmental standards.
Delivery Results: Immediate Cost Reduction & Efficiency Gains
Efficiency Boost: Single-shift output increased by 25%, with the production cycle time shortened from 4 hours/batch to 3 hours/batch.
Cost Savings: Annual savings on electricity and resin waste now amount to approximately 1.2 million RMB.
Management Upgrade: Achieved "One Item, One Code" quality traceability, allowing instant retrieval of insulation processing data for any motor produced.
Client Testimonial：This renovation not only solved our environmental compliance challenges but also gave our old factory an intelligent 'new heart.' The return on investment period was six months shorter than expected!