The production process of synthetic rattan can vary depending on the manufacturer, but it typically involves the following steps:
1. Raw Material Preparation
Synthetic rattan is made from a polymer, such as polyethene (PE), which is melted and moulded into the desired shape. The raw material is typically supplied in pellet form and must be melted down before use.
Main Materials
The main raw material for synthetic rattan is a polymer, such as polyethene (PE), polyvinyl chloride (PVC), or polypropylene (PP). These polymers are commonly used because they are durable, lightweight, and weather-resistant, making them ideal for outdoor furniture applications.
Auxiliary Materials
In addition to the main polymer, there are several auxiliary materials used in the production of synthetic rattan, including:
- Stabilizers: Stabilizers are added to the polymer to improve its stability and resistance to UV radiation and other environmental factors.
- Pigments: Pigments are added to the polymer to provide colour and improve the final product’s appearance.
- Lubricants: Lubricants are added to the polymer to improve its flow properties and reduce the friction between the polymer and the extruder.
- Additives: Additives are added to the polymer to improve its properties, such as strength, flexibility, and abrasion resistance.
- Reinforcing materials: Reinforcing materials, such as glass fibres, can be added to the polymer to increase its strength and durability.
These are some of the auxiliary materials used in the production of synthetic rattan. The specific types and quantities of these materials will vary depending on the manufacturer and the desired properties of the final product. The goal is to create a synthetic rattan material that is strong, durable, and suitable for outdoor use while also being aesthetically pleasing and comfortable.
It is difficult to say which of the auxiliary materials used in the production of synthetic rattan is the most expensive, as the cost will vary depending on several factors, including the specific type of material, the quantity used, and the location of the manufacturer.
Generally, reinforcing materials, such as glass fibres, tend to be more expensive than other auxiliary materials, such as stabilizers or pigments, because they add significantly to the strength and durability of the final product and therefore require more material used. Additionally, the production process for reinforcing materials is typically more complex, which can also contribute to their higher cost.
That being said, the overall cost of the auxiliary materials is relatively small compared to the cost of the main polymer, and the price of the final product is largely determined by the cost of the polymer and the manufacturing process used to produce the synthetic rattan.
2. Extrusion & Cooling
The melted polymer is then extruded through a die to form the synthetic rattan fibres. The fibbers are cooled and cut to the desired length.
The raw material is first fed into an extruder, which melts and mixes the polymer. The melted polymer is then forced through a die, which is a metal plate cut into a specific shape. As the polymer exits the die, it is cooled and solidified, forming individual fibres. The fibres are then cut to the desired length, and the process is repeated to produce the amount of material needed for the final product.
The extrusion process is a crucial step in producing synthetic rattan, as it determines the final product’s quality, strength, and durability. Workers must carefully control the process to ensure that the correct temperature and pressure are maintained and that the polymer is properly mixed and melted, which helps to ensure that the synthetic rattan fibres are of consistent quality and that the final product is strong, durable, and able to withstand the rigours of daily use.
3. Rolling
Rollers are used specifically for packaging strips of synthetic rattan. These rollers are typically used to wind the strips into a coil or spool, making transporting and storing the material easier.
The purpose of these rollers is to compact the strips into a compact and manageable form, which helps to save space and prevent the material from becoming tangled or damaged during storage or transportation. They work by applying pressure to the strips and winding them into a coil or spool, which helps to keep the material organized and protected.
These rollers are typically used at the end of the production process after the strips have been shaped and moulded into the desired size and shape. By using these rollers, the manufacturer can ensure that the final product is packaged and stored properly, which helps to protect the material and maintain its quality and performance characteristics.
4. Packaging
The rattan material is typically packaged in bags or boxes, depending on the quantity and size of the material.
The bags are usually made of strong and durable materials, such as polyethene or polypropylene, to protect the material from moisture and dust.
The material is usually packaged in boxes or on wooden pallets for larger quantities of rattan material. The boxes are usually made from corrugated cardboard or plastic. They are designed to protect the material from moisture, dust, and other environmental factors that could damage or degrade the quality of the material.
The bags and boxes are typically sealed with tape or other fasteners to prevent the rattan material from becoming contaminated or damaged during storage or transportation.
Overall, the packaging of rattan material is designed to protect the material and maintain its quality and performance characteristics so that you can use it to produce high-quality rattan furniture products.
Conclusion
Above is a general overview of the production process for synthetic rattan. The exact process may vary depending on the manufacturer and the type of furniture being produced. For instance, some other manufacturers use rolling machines that combine the processes of melting, cooling and forming shapes and sizes into one machine.
Leisure Touch Rattan’s goal in the process is always to create high-quality furniture that is durable, stylish, and comfortable. Our factory has a competitive output capacity of 3500 tons per month. With over 200 skillful workers and an exclusive development and research team, we are walking steadily towards a future motivated by cutting-edge technology, providing you with leading-industry excellent synthetic wicker rattan material. Let’s start a business talk today!
