A pultrusion line is a machine, a set of dies, a creel and resin system, a saw and a control cabinet, shipped in pieces and reassembled on the customer's floor. The machine itself is the smaller risk. The larger risk is the gap between a line that runs and a team that can run it, and that gap is closed by the sequence below.
Two parties appear in every document. The manufacturer, Henan Zhongsheng Composite Material Co., Ltd. in Xinxiang, Henan, builds the equipment and is the warranty party. The Shanghai export company is the exporter of record and the contracting party on the purchase contract; its legal name appears on the quotation. Commissioning engineers travel from the factory.
Pre-shipment factory acceptance test (FAT)
The FAT is run at the factory in Xinxiang before the line is packed. The customer or an appointed inspector attends in person or by video. Its purpose is to prove, against written criteria, that the machine meets the contract specification and that the customer's dies produce profile within tolerance. A FAT that is not against written criteria is a demonstration, not a test.
The scope and pass/fail criteria below are the template the FAT protocol is built from. Items marked TBD are decided per contract because they depend on the machine model, the number of dies and the profiles the customer will run.
| Test item | Method | Pass criterion |
|---|---|---|
| Mechanical completeness | Check against packing list and general-arrangement drawing | All items present; no transport-only fixings missing |
| Pull force | Load cell between gripper and anchored test bar at rated hydraulic pressure | TBD · ask factory |
| Clamp force | Measured at gripper at rated pressure | TBD · ask factory |
| Speed range and stability | Encoder reading at minimum, midpoint and maximum setpoint over a timed run | TBD · ask factory |
| Heating zones | Each zone heated to setpoint; thermocouple reading logged against an independent probe | TBD · ask factory |
| Control panel | Function test of every control, interlock and emergency stop; verification of electrical standard specified in contract (CE or UL 508A option) | Every function operates as drawn; wiring matches the approved schematic |
| Voltage and frequency | Confirm cabinet, motors and heaters are built for the ordered supply (380 V 50 Hz or 480 V 60 Hz) | Matches contract |
| Flying saw | Cut length repeatability over a run of cuts | TBD · ask factory |
| Trial pull with customer die | Pull a length of profile with the customer's resin and reinforcement, or a factory-standard equivalent agreed in advance | TBD · ask factory |
| Profile dimensions | Measure trial profile against the agreed drawing and tolerance class | TBD · ask factory |
| Documentation | Operating manual, electrical schematics, hydraulic schematics, parts list, die drawings and FAT record handed over | Complete set in the contract language |
Payment milestones, electrical compatibility and independent inspection are covered in the buying a pultrusion line from China checklist
Shipping and site preparation
While the line is in transit the customer prepares the site. Everything on this list is on the critical path: a commissioning engineer who arrives to find no compressed air or the wrong supply voltage spends paid days waiting. Dimensions, loads and utility ratings are given in the general-arrangement drawing and utility schedule issued for the specific machine; the items below are the categories to prepare, not the values.
Building and foundation
- Floor area for the full line length, including creel, resin station, die station, puller, saw and run-out table, plus working space on both sides
- Level floor rated for the machine mass and anchor-bolt pattern on the foundation drawing
- Overhead clearance for die handling and crane or forklift access for installation
- Separate ventilated area or enclosure for resin mixing and storage
- Finished floor and lighting before equipment arrives; no concrete pours after delivery
Utilities
- Electrical supply at the ordered voltage and frequency, with a lockable isolator sized to the installed power on the utility schedule
- Earthing (grounding) to local code
- Compressed air at the pressure and dryness on the utility schedule, with a drier and receiver
- Exhaust extraction over the resin bath or injection station and at the saw, to local emission rules
- Cooling water if the machine or saw specifies it
- Network connection at the control cabinet for remote support
Customs clearance, inland transport, offloading and placing the machine on the foundation are the customer's responsibility unless the contract says otherwise. The exporter provides the packing list, HS codes and the documents the destination customs authority requires.
Installation and site acceptance test (SAT)
Factory engineers arrive after the equipment is on its foundation and the utilities are live. Installation covers alignment of the die station, puller and saw along the line axis, connection and checking of hydraulics, electrics and heaters, loading the control program and dry-running every axis. The SAT then repeats the key FAT measurements on site to prove nothing was damaged in transit and that the local power and air deliver what the machine needs.
- Mechanical installation and alignment; hydraulic and pneumatic connection; electrical connection by a locally licensed electrician under the factory engineer's direction
- Power-up, control function test and interlock check; heater zone test
- Dry run of puller, saw and axes without fiber
- First wet pull with the customer's resin and reinforcement on the first die; parameter record started
- SAT measurements: pull and clamp force, speed, zone temperatures, cut length, profile dimensions against drawing
- SAT record signed by customer and factory engineer; open items listed with owner and date
| Item | Factory | Customer |
|---|---|---|
| Foundation, utilities, offloading, placement | Drawings and utility schedule | Execution |
| Mechanical installation and alignment | Lead and supervise | Labor, lifting equipment |
| Electrical connection | Direct and check | Licensed electrician, cable to isolator |
| Commissioning engineers on site | Number and duration per contract | Travel, accommodation and local transport as agreed in the contract |
| Consumables for SAT (resin, fiber, release agent) | Specification | Supply |
| SAT protocol and record | Draft and execute | Witness and sign |
| Duration on site | TBD · ask factory | Prepare site so the period is not extended |
Operator and process-technician training
Training is for two roles. Operators run the line safely shift after shift: threading, start-up, steady-state monitoring, die change and shutdown. The process technician owns the parameter record, tunes speed and temperature for new dies and resins, diagnoses defects and decides when a die needs rework. A line with trained operators and no process technician will run the first profile well and struggle with the second.
What is taught
Operators
- Safety: interlocks, emergency stops, hot die handling, resin and styrene handling, saw guarding
- Creel loading, roving threading, mat and veil feeding, tension setting
- Resin mixing procedure and pot life, or injection unit operation
- Start-up sequence, steady-state checks, reading pull force as a health signal
- Die change: removal, cleaning, storage, installation and re-heat
- Shutdown and purge, daily cleaning, log keeping
Process technicians
- Three-zone temperature profile and gel-point placement
- Speed versus cure; tuning a new die from a conservative start
- Defect diagnosis: voids, dry spots, sloughing, surface marks, bow and twist, undercure
- Dimensional and Barcol hardness inspection against the tolerance class
- Die inspection and the rework or re-chrome decision
- Maintaining the parameter record and preparing a trial report
The number of trainees and the days of on-site training are set in the contract and shown as TBD below until the factory confirms its standard package. Training is in English through the factory engineer and, where required, an interpreter; manuals are supplied in the contract language.
The first four weeks after delivery
- 01
Week 1: installation and SAT
Factory engineers with customer operators · TBD
Factory engineers install, align and commission the line, run the first wet pull and complete the SAT record. Operators shadow every step and take over threading and start-up under supervision by the end of the week.
- 02
Week 2: supervised production on the first die
Customer operators, factory engineer supervising · TBD
Operators run shifts on the first profile with the factory engineer present. The process technician builds the parameter record, learns the tuning sequence and inspects profile against the drawing. Common defects are induced deliberately and corrected.
- 03
Week 3: second die and die change
Customer team, factory engineer observing · TBD
The team performs a full die change, re-heat and start-up on the second profile with the engineer observing rather than leading. Tuning from a conservative start to production speed is done by the process technician.
- 04
Week 4: independent operation and handover
Customer team; factory engineer on call · TBD
The customer team runs without the engineer on the floor. Open items from the SAT are closed, remote support is tested end to end, the spare-parts kit is checked against its list and the handover record is signed.
| Item | Standard package |
|---|---|
| Operators trained on site | TBD · ask factory |
| Process technicians trained on site | TBD · ask factory |
| Days of on-site training included | TBD · ask factory |
| Training at the factory in Xinxiang before shipment | TBD · ask factory |
| Language of instruction | English via factory engineer; interpreter where required |
| Training materials | Operating manual, parameter record template, defect reference in contract language |
Spare-parts kit
A first-year spare-parts kit ships with the line so that a failed wear part does not stop production while a replacement crosses an ocean. The kit list is part of the quotation and is confirmed against the final machine configuration. Items in the kit are the categories below; quantities are per contract.
- Heater cartridges and thermocouples for every zone type on the die station
- Gripper pads and clamp seals for the puller
- Hydraulic seals, filters and a hydraulic hose set
- Saw blades and saw drive belt
- Ceramic guide eyes, preform plate blanks and creel tension components
- Control cabinet fuses, relays and one of each critical electronic module, as specified in the contract
- Resin pump or injection unit wear parts where fitted
Parts carry the manufacturer's part numbers and the kit list identifies the generic equivalent for commodity items (bearings, seals, fuses) so the customer can source locally if needed. Proprietary items are supplied through the exporter.
Remote support
After handover, support runs through a named contact at the exporter and the factory engineer who commissioned the line. The control cabinet is prepared for remote access over the customer's network connection, so the factory can view the control program and alarm history when the customer permits. Video calls from the line are the first response to a process problem; a site visit is arranged when remote diagnosis is not enough.
| Item | Scope |
|---|---|
| First response channel | Email and messaging to the exporter's named contact; video call with the factory engineer |
| Remote access to control system | Available when enabled by the customer; access is customer-controlled |
| Response time commitment | TBD · ask factory |
| Software and parameter backups | Control program and parameter records backed up at handover; customer holds a copy |
| Follow-up site visit | Quoted separately unless included in the contract |
Warranty
The warranty party is the manufacturer, Henan Zhongsheng Composite Material Co., Ltd. The contracting party on the purchase contract is the Shanghai export company, which handles claims, documentation and shipment of warranty parts. Warranty period, exclusions (consumables, wear parts, damage from site utilities outside specification) and the claims procedure are written in the contract and are listed below as TBD until confirmed.
| Item | Position |
|---|---|
| Warranty party | Henan Zhongsheng Composite Material Co., Ltd. (manufacturer) |
| Contracting party | The Shanghai export company (exporter of record; legal name on quotation) |
| Warranty period | TBD · ask factory |
| Start of warranty | TBD · ask factory |
| Covered | Design, material and workmanship defects in machine, control system and dies as described in the contract |
| Excluded | Consumables and wear parts; damage from utilities outside the utility schedule; unauthorized modification |
| Claims route | Through the exporter's named contact; factory engineer diagnoses remotely first |
What a turnkey line includes, what is quoted separately and how the machine, dies and ancillaries are specified is on the turnkey pultrusion line overview
Buyers who want to audit the factory before the FAT, or combine the FAT with a plant visit, can arrange it through the manufacturing partner page
Questions buyers ask
- What is included in a pultrusion line FAT?
- Mechanical completeness, pull and clamp force, speed range, heater zone performance, control panel and interlocks, electrical standard and supply voltage, saw cut length, a trial pull with the customer's die and measurement of the trial profile against drawing. Pass/fail values are written into the FAT protocol per contract.
- Can the FAT be witnessed by a third party?
- Yes. Name the inspector in the contract and tie the pre-shipment payment milestone to the signed FAT record. Video witnessing is available if nobody can travel to Xinxiang.
- What does the customer need to prepare before installation?
- A level, load-rated floor to the foundation drawing, electrical supply at the ordered voltage and frequency with an isolator, compressed air to the utility schedule, exhaust extraction at the resin station and saw, a ventilated resin area, lifting equipment and a network connection for remote support.
- How many operators are trained and for how long?
- The number of operators and process technicians and the days of on-site training are set in the contract. The standard package is shown as TBD on this page until the factory confirms it; ask for it in the quotation.
- Who provides the warranty on a pultrusion line bought through the exporter?
- The manufacturer, Henan Zhongsheng Composite Material Co., Ltd., is the warranty party. The Shanghai export company is the contracting party on the purchase contract and handles claims and shipment of warranty parts.
- Is a spare-parts kit included?
- A first-year kit of wear parts (heaters, thermocouples, gripper pads, seals, filters, saw blades, guide eyes, fuses and relays) is listed in the quotation and confirmed against the final machine configuration. Quantities are per contract.
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