Company Introduction
Xi'an Tianlei Rubber Technology Co., Ltd. was established in 2007, located in Xi 'an city, factory area of 22,000 square meters, building area of 12,000 square meters. We have more than 15 different types of product production lines and professional product design and development team, mold development team, production department. Specialized in cork product development, cork material design and sales integration unit. We are engaged in the production of high quality cork coasters, cork stoppers, cork covers, cork yoga and fitness products.
Our company's Cork Stoppers , Cork yoga and Cork coasters are exported to the United States, Britain, Canada, Pakistan, India, Russia, Germany and other more than 40 countries.We can meet your various specifications of O D M, O E D projects, we look forward to more cooperation. As a leading enterprise in China's cork rubber industry.
Focusing on R&D
Tianlei Cork Company deeply understands that innovation is the core driving force of corporate development. As an industry-leading cork product solutions provider, we continuously invest heavily in building and strengthening our R&D system, covering the entire lifecycle from concept inception to industrialization. In particular, we demonstrate exceptional technical strength and efficient transfer of results during the three key stages of product pre-testing (proof of concept), pilot production (small-scale trial production), and R&D completion (industrialization).
Core R&D Capabilities Demonstrated
Foresight and Proof of Concept (Pre-testing)
In-depth Market Insights and Technology Pre-research: Our R&D center closely monitors global market trends, customer pain points, and cutting-edge technologies (such as new materials science, environmentally friendly processes, and intelligent manufacturing) to conduct forward-looking technology development and concept exploration.
Laboratory-grade Prototype Development and Validation: In the early stages of conception, we utilize our advanced materials analysis laboratory (equipped with spectrometers, electron microscopes, and mechanical testing equipment) to conduct formulation research, structural design simulations, and basic performance testing. Proof of concept feasibility is achieved in a laboratory setting through rapid prototyping (such as 3D printing and small molds).
Strict Screening and Evaluation: Potential new products/processes are comprehensively evaluated across multiple dimensions, including technology, market, cost, and environmental considerations, to ensure they possess commercial potential and competitive advantages, laying a solid scientific foundation for the pilot stage.
Engineering Scale-Up and Process Optimization (Pilot Stage - A Core Advantage)
Professional Pilot Plant and Equipment: Tianlei Cork Co., Ltd. boasts an industry-leading, large-scale, professional pilot plant. This facility is equipped with a complete, miniaturized production line (covering key steps such as raw material pretreatment, core process equipment, post-processing, and sorting) capable of simulating actual production environments.
Refined Process Parameter Research: During the pilot stage, the core task is to address the "scalability" of laboratory results to industrial production. Through systematic DOE (Design of Experiments), we precisely optimize various process parameters (such as temperature, pressure, time, and formulation ratios) to ensure consistent product quality and performance.
Small-Scale Trial Production and Data Accumulation: Conduct small-scale trial production to produce samples for customer trials and market testing. Detailed data is collected to evaluate key indicators such as production efficiency, energy consumption, cost, equipment compatibility, and product consistency.
Reliability Testing and Standard Development: Pilot products undergo comprehensive durability testing, environmental adaptability testing (temperature, humidity, and light exposure), and application scenario simulation testing to verify actual product performance and provide a basis for the development of strict corporate/industry standards.
Risk Identification and Resolution: Pilot production is a critical step in identifying and resolving potential production issues, supply chain issues, and quality risks. Our robust pilot production capabilities significantly reduce industrialization risks and shorten product time-to-market.
Efficient Industrialization and Continuous Iteration (R&D Completed)
Mature Industrialization Transfer Mechanism: Leveraging the reliable data accumulated during the pilot phase and validated process packages, we have an efficient technology transfer process that enables rapid and accurate integration of R&D findings into large-scale production lines.
Production Process Solidification and Quality Control: The R&D team collaborates closely with production and quality departments to solidify production process parameters and establish a comprehensive quality control system (including online testing and SPC statistical process control) to ensure high product consistency from the lab to the market.
Product Launch and Market Feedback Closed Loop: R&D doesn't end with mass production. We have established a rapid response mechanism for market feedback, collecting customer usage data and feedback for continuous product improvement and the development of next-generation products.
Intellectual Property Protection and Development: We actively apply for patents (inventions, utility models, and designs) and protect know-how for R&D results, building a competitive advantage.
A Solid Foundation Supporting R&D Strength
High-Level R&D Team: We bring together PhDs, Masters, and experienced engineers from diverse fields, including materials science, chemical engineering, mechanical design, and automation control, to form a strong interdisciplinary R&D force.
Advanced R&D Facilities: We continuously invest in a modern R&D center, analytical testing laboratories, and a professional pilot plant equipped with world-class R&D, testing, and pilot production equipment.
Deep Integration of Industry, Academia, and Research: We establish long-term strategic partnerships with renowned domestic and international universities and research institutions to jointly overcome technological challenges and accelerate innovation.
Continuous R&D Investment: We invest a fixed percentage of our annual sales revenue in R&D to ensure the uninterrupted momentum of our innovation engine.
R&D Achievements and Value
Tianlei Cork's strong R&D capabilities, particularly its exceptional capabilities in pilot production, enable us to:
Quickly Respond to Market Demand: We efficiently translate customer needs into innovative products.
Improve Product Performance and Quality: We continuously launch cork products with superior performance, improved environmental friendliness, and a wider range of applications.
Optimize Production Processes and Reduce Costs: We improve efficiency through process innovation, reduce energy and material consumption, and enhance market competitiveness.
Leading Industry Technological Development: We promote advancements in cork materials and their application technologies, setting industry benchmarks.
Creating Greater Value for Customers: We provide technologically advanced, reliable, and stable product solutions.
Conclusion
Tianlei Cork Company has established a comprehensive R&D system encompassing the entire product innovation chain, centered on robust pre-pilot exploration, robust pilot-to-pilot transformation capabilities, and efficient industrialization. We are not only a manufacturer of cork products, but also an industry leader driven by technological innovation. Choosing Tianlei means you're choosing cutting-edge technology, reliable quality, and a future-oriented innovative partner.
Production
End-to-End Production Process: From Natural Cork to High-Value Finished Products
Tianlei Cork has established an intelligent, standardized, and eco-friendly integrated production system. We maintain strict quality control at every stage from raw material intake to finished product delivery, ensuring exceptional performance and consistent product quality. The core process flow is as follows:
1. Raw Material Selection & Pre-Processing
Raw Material Sourcing: Strict procurement of natural cork oak bark (raw cork material) exclusively from premium growing regions like Portugal and the Mediterranean, ensuring sustainable, pollution-free origins.
Raw Material Grading: Precision grading by thickness, density, color, and other parameters using a fully automated optical sorting system (equipped with high-resolution cameras and AI algorithms).
Washing & Sterilization: Raw material undergoes high-pressure spray washing to remove impurities, followed by sterilization in a high-temperature steam chamber (120°C+/248°F+) to eliminate microorganisms, ensuring hygienic safety.
Stabilization: Washed material is stored in a temperature- and humidity-controlled stabilization chamber for 3-6 months to relieve internal stresses and enhance subsequent processing stability.
2. Core Process: Granulation → Agglomeration → Molding
Precision Granulation:
Utilizes low-noise superfine grinding units (German technology) to reduce cork blocks into 0.5-5mm granules.
Key Equipment: Turbine mill (with anti-overheating design) + multi-stage vibrating screening system (precise particle size distribution control).
Eco-Friendly Binder Preparation:
Employs food-grade, water-based polyurethane adhesive prepared and matured by a fully automatic adhesive dispensing system (accuracy ±0.1%).
Granules and binder are uniformly mixed (≥99% homogeneity) in a twin-screw mixer.
High-Temperature & High-Pressure Molding:
The mixture is fed into a fully automatic hydraulic molding line:
Mold Loading: Robotic auto-loading with positioning accuracy ±0.05mm.
Hot Press Curing: Constant temperature/pressure curing for 30-90 minutes in CNC-controlled hot presses (200-400 tons pressure, 160-200°C/320-392°F) to form high-density slabs.
Specialty Products (Steam Expansion Process): Granules naturally expand and bond within high-temperature steam autoclaves, producing 100% natural cork boards with zero formaldehyde added.
3. Precision Post-Processing & Finishing
Thickness Calibration & Sanding:
Slabs undergo double-sided precision sanding on three-roller calibrating sanders (Italian import), controlling thickness tolerance within ±0.1mm.
Cutting & Profiling:
Complex shapes are cut with high efficiency and precision (±0.2mm accuracy) using CNC cutting centers (laser positioning + diamond tooling).
Surface Finishing:
UV Coating Line: Fully automatic roller/spray application of UV coating, instantly cured in a hybrid (mercury vapor + LED) light-curing tunnel to enhance abrasion and stain resistance.
Natural Wax Impregnation: Selected products undergo vacuum-pressure impregnation with food-grade wood wax for deep penetration, significantly boosting waterproofing.
Functional Treatments (Optional):
Flame Retardancy Line: Impregnation-drying process imparts Class B1 flame retardancy.
Soundproof Backing Lamination: Precise lamination of EVA/rubber acoustic underlayment using hot-melt coating compounders.
4. Comprehensive Quality Control & Packaging
Automated QC:
In-Line Vision Inspection System: Real-time surface scanning for defects (cracks, color variations).
Physical Property Testing: Daily lab sampling for key metrics: density, compression recovery rate (≥90%), abrasion resistance (≥6000 cycles), formaldehyde emissions (non-detectable).
Intelligent Packaging:
Products receive dust protection via automatic film wrapping, are palletized by robotic arms, and enter a smart warehouse system (WMS-controlled) for precise inventory management.
Core Production Capabilities & Equipment Advantages
I. Smart Production Equipment (Key Equipment Highlights)
| Process Step | Core Equipment | Technical Advantage | Brand/Sophistication |
|---|---|---|---|
| Raw Mat. Proc. | AI Optical Sorter + HT Steam Sterilizer | >99.9% impurity ID, +50% sterilization efficiency | Swiss Tech + Custom |
| Granulation/Sift | Turbine Superfine Grinder + Multi-Stage Sifters | ±0.1mm particle control, -30% energy use | Bühler Tech (Germany) |
| Molding/Curing | CNC Hydraulic Hot Press (400-ton) | Closed-loop P/T control, ΔT ≤±2°C | Custom High-End (Domestic) |
| Steam Expansion Autoclave (10m³) | >95% pressure uniformity, binder-free molding | Patented In-House | |
| Surface Finish | CNC Cutting Center + UV Cure Coating Line | 200 sheets/hr cut rate, coating hardness ≥3H | SCM (Italy) + Ransburg (Japan) |
| Quality Control | In-Line Vision System + Auto Phys. Test Lab | 99.5% defect detection, real-time MES data upload | ISRA (Germany) + Instron (USA) |
II. Scalable Production Capacity
Output Scale:
Sheet Material: 30 million m²/year (expandable to 50 million m²)
Roll Goods: 10 million linear meters/year
Custom Components: 2 million pieces/year
Production Line Flexibility:
Supports 72-hour quick changeovers, handles 50+ concurrent SKUs.
Compatible with full specifications: Thickness 1mm-50mm, Size 50x50mm to 2400x1200mm.
III. Sustainable Manufacturing System
Green Production:
Waste Heat Recovery: Molding process heat reused for raw material drying, reducing energy consumption by 25%.
Dust Capture Rate >99%: Central dust collection + pulse-jet baghouse filtration, meeting ISO 14001 standards.
Zero-Waste Commitment:
100% scrap material recycled/reprocessed into low-density filler, achieving closed-loop resource utilization.
Quality Control
TianleiCork Company: Redefining Cork Excellence Through Extreme Quality Control
Tri-Shield Quality Fortress: Prevention · Precision · Zero Tolerance
1. End-to-End Quality Control Architecture
2. Core QC Processes & Technological Breakthroughs
2.1. Raw Material Control (Incoming Pass Rate ≥99.8%)
2.2 Process Monitoring (Critical Process CPK ≥1.67)
| Control Point | Technology | Tolerance | Anomaly Response |
|---|---|---|---|
| Mixing Uniformity | Online NIR Spectrometer | Adhesive dispersion ≤1.5% | Auto-adhesive dosing |
| Hot-Press Temp Field | Distributed Fiber Optic Sensors | Surface ΔT ≤2°C | Adaptive pressure compensation |
| Sanding Thickness | Laser Gauges + Closed-Loop System | Thickness ±0.08mm | Automatic belt adjustment |
| UV Curing Intensity | Radiometers + Energy Integrators | Output fluctuation ≤3% | Dynamic conveyor speed control |
2.3. 100% Product Testing (Reject Rate ≤0.25%)
AI Sorting System:
Hyperspectral imaging detects internal bark defects (voids/insect damage)
Laser thickness gauges enable automatic grading (±0.05mm precision)
Biochemical Safety Testing:
GC-MS (Gas Chromatography-Mass Spectrometry) screens pesticides/heavy metals
Microbial incubators (ISO 22196 compliant) validate sterility rates
Automated Inspection Line:
3D Vision System: Detects 0.1mm² surface defects (cracks/dents)
Acoustic Resonance Analyzer: Verifies structural integrity via vibration spectra
Destructive Lab Testing:
Compression Resilience: ASTM F1551 compliance, ≥92% rebound after 100k cycles
Accelerated Aging: Xenon-arc chamber simulates 5-year UV exposure (ΔE≤1.5)
VOC Emissions: Chamber method (EN 16516) - Formaldehyde/Benzenes "non-detectable"
Fire Resistance: Cone calorimeter (CONE) testing - Smoke density ≤15 (Class A per GB)
3. Intelligent QC Hub
Quality Dashboard (Q-Dashboard)
Real-time analysis of 2,000+ sensor data points with AI risk prediction
Automated SPC (Statistical Process Control) CPK/PPK trend mapping
Unique QR code per product: Full traceability of raw material batches, process parameters, and test records
4. Certifications & Standard Leadership
Certifications:
✅ ISO 9001:2015 (Quality Management)
✅ ISO 14001 (Environmental Management)
✅ FSC® COC (Forest Stewardship Council® Chain-of-Custody)
✅ GREENGUARD GOLD (Indoor Air Quality Gold Certification)
Standardization:
Lead developer of QB/T ** Industry Standard for Composite Cork Flooring
Testing methodologies accredited by CNAS (China National Accreditation Service)
5. Customer Value Assurance
Quality Warranty: Lifetime product liability coverage via global insurer
On-Site QC: Third-party inspection agencies welcome for 24/7 plant monitoring
Open-Book Quality: Raw material & finished product test data shared monthly with strategic partners
The TianleiCork Quality Pledge
We govern production with laboratory-grade precision,
Apply pharmaceutical-grade rigor to every square foot of cork,
Because we understand:
You're not selecting a material – you're investing in guaranteed spatial excellence.
