Kurtz Ersa Magazine


Optimised helmet production at Yee Fung Group

More and more moulded parts made of EPS and EPP, such as sports helmets, sun visors and rear seat benches, require various metal or polymer inserts to be inserted in the machine and then foamed over. With a standard machine, this means longer cycle times and thus lower productivity, since it cannot be used for production during the insertion process.


Our long-standing customer, Yee Fung Polyfoam Limited / Hong Kong Sports from China, also faced this problem. Hong Kong Sports is one of the largest helmet OEM manufacturers for ski, motorcycle, and mountain climbing and bicycle helmets with production facilities in Sha Jin and Dongguan. The company has been a Kurtz customer for more than 40 years now and produces more than 6.5 million units per year.

For his helmet production, Hong Kong Sports wanted an automatic machine for moulded parts which would make increased productivity and reduced personnel deployment possible, take up less space than a shuttle machine and deliver consistently high quality. Kurtz took up the challenge and, following close cooperation with the customer, the Kurtz ROTO FOAMER 911 was born – the specialist for production of moulded parts with inserts.


These are automatic machines for moulded parts with a foam area of 900 x 1,100 mm for processing EPS and EPP which are equipped with a rotating double steam chamber on what is otherwise the stationary steam chamber side. While foaming takes place on one side, the helmet inserts can be set in place manually – or even automatically in future – on the other. In addition, this machine is flexible enough to be used as a standard machine without inserts.


Go to product page Kurtz ROTO FOAMER

The first ROTO FOAMER was set up and put into operation at Hong Kong Sports in Sha Jin at the end of February 2017. During the running-in phase, Hong Kong Sports was trained in handling the machine by a German/Chinese Kurtz team made up of process and service engineers, and the ROTO FOAMER was able to be integrated in ongoing helmet production within a very short time.


Following the first few months in full operation and positive customer feedback, it can already be said that the ROTO FOAMER is exceeding expectations. This is also indicated by the fact that Hong Kong Sports is already planning to gradually replace older machines by Kurtz ROTO FOAMERs in various sizes, thus further increasing productivity and cutting costs. In the meantime, the second machine in the 911 size is already on its way to China.


New Kurtz Ersa Image Film

Kurtz Ersa - YouTube Channel

“And … action!” was the instruction from the film crew to be heard at all kinds of different locations at Kurtz Ersa in spring. The film team was out and about on a mission to produce the new Kurtz Ersa image film. With “speed” as a leitmotiv, the film shows what Kurtz Ersa stands for: innovation, drive and high-tech processes. With a range of scenes and fast editing sequences the clip shows in just over 2 minutes what it is that characterises Kurtz Ersa. Enjoy watching it!


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