Huakai NonwovenYangzhou Huakai Nonwoven Machinery Co., Ltd.
Huakai NonwovenYangzhou Huakai Nonwoven Machinery Co., Ltd.
Huakai's LYBG103-400 line produces needle-punched substrate for PU and PVC synthetic leather (artificial leather), shoe insole board and toe puff, automotive carpet base and headliner, and furniture leather. Finished width 3,600 mm, fabric weight 150–2,000 gsm, output up to 500 kg/h — one line covering footwear, automotive and furniture applications.
The line produces the needle-punched nonwoven base fabric that PU and PVC synthetic leather is coated onto. The substrate has to present a dense, even surface with consistent thickness, because any irregularity in the web shows through the coating layer — either as surface defects or as uneven coating pickup. Huakai builds this line around a twin-cylinder twin-doffer carding section and a high-speed needle loom, which gives the web the density and regularity that coating requires.
Fabric weight runs from 150 to 2,000 gsm on the same line, so a producer can cover light garment and furniture leather base as well as heavier technical substrate without adding a second line.
Needle-punched nonwoven is the standard substrate for shoe insole board (also called insole board, counter board or toe puff), where it replaces or reinforces cellulose board. The requirement is different from leather substrate: insole board needs stiffness and dimensional stability rather than surface smoothness, so it is pressed and often impregnated after needling.
Huakai supplies needle punching lines for shoe material production, from bale opener through carding, cross lapping, pre-needling, main needling and cutting & winding. Fabric weight for insole board typically sits in the middle of the 150–2,000 gsm range; tell us your board thickness and stiffness target and we size the needling and calender section accordingly.
Our needle punching lines have been in continuous production at Yizheng Bontex (仪征邦泰), a footwear substrate manufacturer based in Yizheng, Jiangsu, for close to 20 years. Long-running installations like this are the reason the shoe material configuration of this line is not a new development for us — we can share reference details at enquiry stage.
Plant layout — LYBG103-400 PU leather substrate & automotive carpet base line
Process flow — from fibre opening to finished roll
| Main parameter | Value |
|---|---|
| Carding output width | 2500 mm |
| Lapping output width | 4000 mm |
| Finished product width | 3600 mm |
| Material weight | 150 ~ 2000 g/m² |
| Production speed | 0.5 ~ 6 m/min |
| Production output | 500 kg/h |
| Power capacity | 184 kW |
| Fibres processed | PE, PET, PP, aramid, polyamide |
Bale Opener CYLKB-1300 ×3 · Willowing CYLKS-1500 · CYLJM-1600 · Cabinet Blending CYLMX-2200 · Carding CYLSL/Ⅱ-2500 · Cross Lapper YBG102-250×400 · Feeder YBG301-400 · Pre-needle YBG201D-400 · Needle YBG202D-400 / YBG211D-400 · Storage Rack YBG342-400 · Cutting & Winding YBG401-400 · Control Cabinet.
Every line is engineered around your fibre, fabric weight and required capacity. Contact us for a quotation tailored to your material, working width and line speed.
Yes — both are needle-punched nonwoven in the same general weight range, so the same LYBG103-400 line covers them. What changes is the downstream finishing: synthetic leather substrate goes to coating and needs a smooth, dense surface, while shoe insole board is normally pressed and impregnated for stiffness. If you plan to run both, tell us at enquiry stage so the needling and calender configuration suits both products.
It depends on the coating process and the end use, but the machine range is 150–2,000 gsm. Light garment and furniture leather base sits at the lower end; heavier technical and automotive substrate at the upper end. Give us your target gsm and coating method and we will confirm the needling density and line speed.
It is the same LYBG103-400 line. Automotive carpet base and headliner material are produced on the same needle-punched nonwoven platform as synthetic leather substrate — the difference is fabric weight, surface finish and the downstream processes (moulding for carpet, coating for leather). This is why Huakai names it as one line covering several applications rather than selling separate lines for each.
Yes. Needle looms (YBG201D-400 pre-needler, YBG202D-400 and YBG211D-400 main needlers) are supplied as standalone machines. Most customers take the complete line, because matching carding, lapping and needling as one engineered set avoids web quality problems that appear when machines from different suppliers are combined.
Yangzhou Huakai Nonwoven Machinery Co., Ltd. has built needle punching machines and complete nonwoven lines in Yizheng, Jiangsu, China since 2008. The company holds more than 40 national patents, including utility model patent ZL202221328027.X for the twin-motor up & down stroke needle punching system, and is a member of the China Textile Machinery Association (CTMA). Markets served: India, Turkey, Russia, Kazakhstan, Pakistan, Indonesia, Qatar, Egypt and other markets in the world.