Intercontinental Nonwoven Machinery
ChinaMicrofiber Synthetic LeatherEquipment ReplacementLine Upgrade

Multi-Phase Upgrade and Line Replacement for Shandong Kaitai Microfiber

From 2019 to 2025 ZHOU JI delivered a phased solution for Shandong Kaitai Microfiber Co., Ltd. — from retrofitting competitor lines to supplying multiple sea-island (daisy-island) microfiber base-fabric needle punching lines — evolving into the client’s primary core equipment supplier.

View Project Results Plan a Similar Project
Sea-island microfiber substrate needle punching line at Shandong Kaitai
Multi-phase sea-island microfiber substrate line upgrade and replacement for Shandong Kaitai Microfiber.

Customer background

Customer Background

Shandong Kaitai Microfiber Co., Ltd. is a leading domestic producer of microfiber materials that needed to upgrade and retrofit outdated competitor lines, improving surface suede feel and uniformity while reducing noise and vibration.

The challenge

The Customer’s Production Challenges

Only challenges supported by the original project material are included here.

01

Upgrade outdated lines

Existing competitor lines needed upgrading and retrofitting.

02

Improve surface quality

Better surface suede feel and uniformity were required.

03

Reduce noise & vibration

Production noise and vibration needed to be reduced.

ZHOU JI solution

A Phased Retrofit-to-Replacement Program (2019–2025)

ZHOU JI delivered a phased, deeply integrated solution: a 2019 retrofit phase added a reverse-position needle punch machine to two competitor lines, showing lower noise, reduced vibration and higher operating frequency. The 2019–2025 replacement phase delivered a first 9-machine, 13-board daisy-island line (2019), a top-tier 20-board daisy-island COPET complete line (2022), and further daisy-island lines (2024–2025) with a 3.2 m high-speed card, five-axis high-speed cross-lapper and groove evening machine.

01

Fiber Opening

Open fine / island-type microfibers for a consistent supply.

02

Blending

Maintain uniform fiber composition.

03

Carding

Form an even web for the base fabric.

04

Web Formation

Build the required basis weight and thickness.

05

Multi-Stage Needling

Develop a dense three-dimensional fiber structure.

06

Inspection & Winding

Check uniformity and wind for downstream leather processing.

Equipment configuration

Representative equipment in this line.

Opening and carding equipment referenced as part of the delivered process route.

Contact ZHOU JI for the full project equipment configuration.

Implementation

From Configuration to Production Start-Up

Detailed dates and acceptance records are not disclosed; the steps below show the delivery structure of the project.

Requirement Analysis Review fiber type, finished product target and output requirement.
Line Configuration Match opening, carding, web formation and needle punching equipment to the project goal.
Manufacturing & Inspection Prepare and verify equipment for project delivery.
Commissioning & Start-Up Adjust process conditions and support the customer into stable production.

Project results

Project Results

Results reported in the original project material.

01

Supplier Evolution

ZHOU JI evolved from retrofit provider to the client’s primary core equipment supplier.

02

International Standards

Key indicators — uniformity, apparent density, smoothness, needle marks — and surface suede feel meet international standards.

03

Industry Leadership

The program solidified the client’s industry leadership position.