Turnkey Brake Pad Factory
All Machinery You Need & Process Know-How
Building a brake pad manufacturing plant? Walden Mechatronics delivers an end-to-end turnkey line: layout planning, engineering, automation, commissioning, and training — designed for repeatable quality and scalable output.
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Turnkey Scope (What You Get)
A factory-specific, end-to-end solution — from concept to SAT and operator training.
- Facility & line planning: production flow, layout, and infrastructure needs (electrical / pneumatic / hydraulic).
- Engineering & automation: modular line architecture, safety, PLC/HMI, recipe-based parameters.
- Process know-how: pressure/temperature/time optimization, venting cycles, fast changeovers.
- Commissioning: integration, test production (SAT), and training for stable, reproducible quality.
Production Line Modules
Key machines and stations delivered as modular building blocks (scalable, capacity-driven).
Fully Automatic Press Systems (330 Ton PC/LCV • 500 Ton CV)
Warm press technology engineered for speed and repeatability — up to 5× faster than conventional hot pressing (process-dependent).
- 330 Ton for Passenger Car / LCV lines.
- 500 Ton for Commercial Vehicles (CV) and large-surface pads.
- 2-cavity & 4-cavity tooling options (product-dependent).
- Down to 39-second cycle time on 330-ton warm presses with 2-cavity tooling in high-volume production.
| Feature | 330-Ton Fully Automatic Press | 500-Ton Fully Automatic Press |
|---|---|---|
| Recommended Segment | Passenger Car / LCV | Commercial Vehicles (CV), large pads |
| Typical Tooling | 1–2–4 cavity (product-dependent) | 1–2 cavity (often due to larger pad size) |
| Output Focus | High-volume, fast changeovers | High force for larger surface area |
| Cycle Time (example) | Down to 39s with 2-cavity tooling* | Process-dependent |
| Automation | Recipe-based parameters, full press station automation, conveyor integration | |
High-Precision Filling & Dosing + Underlayer Integration
Underlayer and friction material can be applied sequentially on the same dosing system — simpler line design and cleaner changeovers.
- Eliminates the need for a separate underlayer machine.
- Reduces material losses during recipe changeovers.
- Improves underlayer thickness uniformity.
- Up to 25% original mix / chemical savings with the Underlayer System.
Dust Collection & Recovery Technology
Vacuum-based recovery minimizes waste: dust from filling and grinding can be filtered and returned back to the mix tank.
- Collects dust generated during filling and grinding operations.
- Filters and makes it reusable (return to mixing tank).
- Reduces waste-related costs and improves raw material utilization.
Auxiliary Equipment & Full Line Integration
From press output to downstream steps — integrated stations for uninterrupted flow and standardized quality.
- Press station functions: cleaning, dosing/filling, backplate loading, discharge, conveyor integration.
- Pre-grinding integration for faster and more precise preparation.
- Painting booth + drying ovens can be integrated to reduce labor and standardize finish quality.
- Advanced positive-forming deep molds support correct material flow under demanding conditions.
Plug & Play Logistics • Fast Startup
Container-friendly designs for sea/rail transport. Equipment can be shipped pre-assembled and pre-tested to simplify installation and shorten start-up time.
- Plug & Play: pre-assembled, pre-tested shipping concept.
- Short delivery time: production startup can be achieved within 6–9 months depending on order date.
Key Highlights
Quick facts that matter for investors and project planning.
Request a Turnkey Line Concept
Share your product focus (PC/LCV or CV), target capacity, and available space — we’ll propose the right modular line configuration.
Walden Mechatronics
İzmir / Türkiye
Phone: +90 232 700 25 03 | Fax: +90 232 999 16 26
Website: www.waldenmekatronik.com
Email: info@waldenmekatronik.com