Acoustex installs 250 ton Yangli hydraulic press to manufacture moulded carpets for the new Isuzu D

Aug 06, 2023

Acoustex, a Port Elizabeth, Eastern Cape manufacturer of vehicle trim components, has recently installed a new 250 ton Yangli to manufacture moulded carpets for the new Isuzu D-Max bakkie, which is due to be launched in 2022.

The excitement at Acoustex’s plant began in mid-2021 with the floor preparation for the new production line. The dedicated line includes the Yangli frame type single moving sheet drawing hydraulic press that weighs in at 39 tons. The floor needed reinforcing to support the heavy press and the down force exerted during the moulding process.

“The Yangli press, which is manufactured in China, had an interesting journey to get to Port Elizabeth,” said Thys de Villiers of TRM Supplies, the importers and installers of the press.

Acoustex, a Port Elizabeth, Eastern Cape manufacturer of vehicle trim components, has recently installed a new 250 ton Yangli press. Because of its weight and size the only way to ship it was to use a Break Bulk vessel. At the time of shipping there weren’t many choices and it took three months to finally get a firm booking on a vessel. The other problem was that the vessel used only docks at Durban harbour and road transport on an abnormal truck driving from Durban to Port Elizabeth, which took a further four days

“Because of its weight and size the only way to ship it was to use a Break Bulk vessel.The term Break Bulk relates to trades where the cargoes are carried in unitised form such as palletised, bagged, strapped, bundled, drummed and crated and also non unitised general cargo, for example vehicles, machines and steel. All cargo that cannot be containerised.”

“At the time of shipping there weren’t many choices and it took three months to finally get a firm booking on a vessel. The ship then had to make the journey to South Africa and because cargo ships are in short supply because of pandemic complications, the cost increase in shipping has been horrendous.”

“The other problem was that this vessel only docks at Durban harbour and therefore we had to use road transport on an abnormal truck driving from Durban to Port Elizabeth, which took a further four days.”

“Installation then took a further two weeks.”

“A hydraulic press is used in a variety of different operations across many different working environments. From manufacturing to compacting, hydraulic presses have many uses. One hydraulic press use is to create items such as car parts. From windshield wiper blades to clutches, a hydraulic press can be used to make even the most complex car part. Hydraulic presses are used to shape and assemble many products. This includes a variety of different electrical equipment, not just car parts. Even your thermostat could be made by a hydraulic press.”

The importing, transportation and installation of the 250 ton Yangli press was done by TRM Supplies

“In the automotive industry the presses are generally referred to as mould and trim presses and are used widely in the automotive industry to produce a variety of interior components such as instrument panels, door panels, interior trim, insulation and head, trunk, hood, and rear deck liners. The presses can also be used to create firewalls, foam insulators and to trim metal parts. These automotive mould and trim presses are extremely versatile and can be custom designed to meet a manufacturer’s specific applications. Choosing a mould and trim press for automotive needs requires analysis into process cost, efficiency and other operational requirements. The creativity and complexity of the parts that can be produced with a mould and trim press are endless, and limited to the individual tool sets used in forming.”

“Acoustex manufactures vehicle trim parts such as carpeting, parcel shelves, sound deadening components, injection moulded tailgate covers, vacuum formed TPO mats and vehicle protective covers and seat covers,” explained Andre Swartbooi, Sales Director of Acoustex.

“We have been supplying product to automotive customers such as Ford, BMW, Nissan, Toyota, Mercedes-Benz and more recently Isuzu. This project has been specifically conceived for the manufacture of carpets for the new Isuzu D-Max bakkie.”

The new press will be used to manufacture moulded carpets for the new Isuzu D-Max bakkie, which is due to be launched in 2022

There are many challenges that automobile manufacturer’s face being in such a competitive industry. In addition to producing cars that meet demands of consumers, cost and volume targets, and continuously evolving safety regulations, there are mounting pressures in creating lighter and stronger parts for improved fuel efficiency and abilities to withstand impact.”

“Material selection for mould and trim press processes are paramount to the success of car manufacturers. Aesthetics, formability, finish, weight, colour, touch and feel are all important. Mould and trim produced parts are often required to house and hide wires and electronics, making it easy for assembly, maintenance, and possible replacement. In our case the carpets are hiding the treated metal.”

“The single moving sheet drawing hydraulic press is equipped with automatic loading and unloading operations. The raw material sheet is fed from a decoiler via a straightener and heating unit into the press, which does the forming, trimming and clamping.”

“The table size is 3 000mm by 2 000mm and the press has a 2 500KN (250 ton) nominal force.”

“For deep-drawing applications, hydraulic presses provide exceptional flexibility. They also offer programming versatility, which can be used to optimise them for each specific use for maximum productivity and finished-product integrity.”

“We expect to start producing product early in 2022,” concluded Swartbooi.

For further details contact Acoustex on TEL: 041 407 4111 or visit www.acoustex.co.za or www.trmsupplies.co.za