Manufacture

Our manufacturing facilities occupy an area of more than 200,000 square meters and yield production of over 1,000 models of magnetic cores of over 20 materials, with a total annual production of 12,000 tons. In addition, Spinel is completing an intelligent factory project which will be capable of optimized production, digitized production, visualized workshops, dashboard management and intelligent, automated production.

The first step of the manufacturing process is powdering. The entire powdering workshop covers 6,000 square meters and operates a dry-type production line which has been developed based on our 40+ years’ experience. This line provides the functions of automatic accurate electronic scaling, automatic transfer and central control. Powders manufactured by our company are feature precise formula and excellent formability.

Forming is the second step in magnetic core production. We have acquired over 80 sets of pressing machines of various tonnages. The presses have been imported from Japan and are able to meet the production standards of less than 200-tonnage pressure. The forming workshop produces 3 million magnetic products daily and 100 million every month.

We utilize over 1,200 molds to satisfy every clients customization demands.

The third step of ferrite core production is sintering, which plays a vital role in determining the product’s properties. Spinel is equipped with 10 Toshiba fully-automatic nitrogen protection 19-channel kilns, 2 sets of fully-automatic bell-type 8-workstation furnaces and 1 set of 4-workstation furnace. These kilns and furnaces ensure a daily production of more than 30 tons. Additionally, we have implemented a fully-automatic monitoring system that provides continuous 24-hour testing and is the first fully-automatic monitoring system in the industry.

After sintering, all products must undergo grinding, in order to reach client’s requirements for size and inductance. We have introduced more than 20 grinding machines from Japan, which perform different standard GAP grinding of products.

Sorting is the final process. Only qualified products are packed and sent to clients. Spinel develops many automatic size sorting machines and fully-automatic visual sorting system to replace traditional manual sorting, vastly improving efficiency and product quality. The fully-automatic visual sorting system accomplishes the sorting work of 120 products every minute and guarantees 100% quality.

Workshop Panorama

SPINEL’s manufacturing facilities cover an area of more than 200,000 square meters and yield production of over 1,000 models of magnetic cores of over 20 materials, with a total annual production of 12,000 tons.

Intelligent Factory Project

SPINEL’s intelligent factory project is intended for increased efficiency. We undertake this project in order to improve technology for both MES system and production lines. This system can achieve a wide range of management modes, such as optimized production, digitized production, visualized workshops, dashboard management, intelligent production, etc.

Manufacturing starts automatically after a customer’s order is received. This system can monitor the implementation of all working procedures.

Each and every workshop is equipped with a LED display board, which allows operators to accurately manage the schedule of the workshop.

The industrial control system supports all working procedures. It helps to seek information about the operating instructions, technical standards, production records and the hours worked.

Powdering Workshop

Powdering is the first step of the manufacturing process. SPINEL’s powdering workshop spans around 6,000 square meters and supports a production capacity of more than 30 tons each day.

As seen in this picture, our electronic scale system works in a fully automated mode. It can carry out the weighing and mixing of three different kinds of raw materials fast and precisely.

This equipment is used to mix the powder completely. Then the powder is automatically lifted to the 5-meters-high forming machine. This can help us realize a continuous manufacturing process.

Features of the rotary kiln:
1. Indirect heating of natural gas
2. Three-stages preheating
3. The 1st stage heating area: Exhaust gas is used to preheat feedstock for heat recycling and energy savings.
4. The main heating area: Lengthened design results in a fully preheating process.
5. The cooling of the end region is separated from the heating area, which can fulfill the technical cooling requirements.

Rotary kiln

The powder that has been preheated is roughly ground and then mixed with a preset amount of water. A sand mill, as seen in the picture, is used to grind the powder into very small particles. It can realize the accurate measurement of water, powder and batches, with a high level efficiency and zero waste. We also utilize pipeline to transport our fluids.

Demonstrated here are the mixer and spray tower. We run slurry through the spray drying process to form small particles. Then, we use a vibrating screen to get the required powder.

Here is the control room. Powders manufactured by our company are characterized by precise formula and excellent formability, which can provide a guarantee on high-quality magnetic core production.

Forming Workshop

Forming is the second step in magnetic core production. According to customers’ requirements, we can produce magnetic cores in a variety of shapes. Our company has acquired over 80 sets of pressing machines of various tonnages. The presses have been imported from Japan and are able to meet the production standards of less than 200-tonnage pressure. The rotary pressing machine, as seen in this picture, features high efficiency, stable performance and great capacity.

The vertical pressing machine offers a wide adjustment range. It can complete production where some unusual specifications are required.

20 tons vertical pressing machine from Japan

The rotary pressing equipment is working now.

The products that have been treated by various pressing machines are arranged automatically, which results in greatly-reduced labor costs and exceptional-quality products.

Pressing is done on the semi-finished blanks.

Pictured here is our mold storage rack system. We use over 1,200 molds to satisfy every client’s customization demands.

Cemented carbide mold

Blank Storage Area

After pressing has been completed in our workshop, semi-finished blanks are sent into the storage area.

Orderly arranged semi-finished blank storage area

Sintering Area

The third step of ferrite core production is sintering, which plays a vital role in determining the product’s properties. Our company has introduced fully-automated bell-type furnaces and fully-automated nitrogen protection kilns. These kilns and furnaces ensure a daily production of more than 30 tons.

SPINEL has invested in 10 Toshiba fully-automatic nitrogen protection 19-channel kilns.

We have successfully developed a fully-automatic monitoring system that provides continuous 24-hour testing and is the first fully-automatic monitoring system in the industry.

Blanks are ready for sintering in this kiln.

Sintering is being carried out inside the kiln.

The bell-type furnace is a piece of intelligent equipment which automatically performs sintering in a closed loop. It offers a wider adjustment range and a higher level of stability. We have 3 bell-type furnaces available for meeting your top-grade product sintering requirements.

State-of-the-art bell type sintering furnace

Grinding Area

After sintering is done, all products must undergo grinding, in order to reach client’s requirements for size and inductance.

We have introduced more than 20 diverse grinding machines from Japan and Taiwan, which perform different standard GAP grinding of products. These grinding machines are designed exclusively for magnetic cores. Their prominent features include high precision and easy adjustment.

Semi-finished products are ready for going through a grinding machine.

These semi-finished products have been perfectly ground.

Disc-type grinding machine from a Japanese company

Sorting Area

Sorting is the final process in which we sort out our products according to different sizes and appearance. Those products that have been carefully selected will be packed and warehoused. We have developed many automatic size sorting machines and fully-automatic visual sorting system to replace traditional manual sorting, vastly improving efficiency and product quality.

This system can complete the size or appearance sorting process in a fully automated mode. Our product sorting process is adapted to specific requirements. This results in high production efficiency and low failure rate.

The fully-automatic visual sorting system can accomplish the sorting work of 120 products per minute, and it guarantees 100% quality.

The visual system is working now.

Automatically sorting the products by size and appearance

Warehouse

Approximately one million pieces of qualified and well-packaged products

These packages are ready for shipping. We pledge to keep products in perfect conditions.