Everything is based on creating better value for customers
Everything is aimed at better meeting customer needs
In 2017, Copton spent 370 million yuan to build the Industry 4.0 smart factory in accordance with the world's first-class standards.
The smart factory covers an area of 170 mu, including four main parts: tank area, R&D center, comprehensive workshop and automatic storage center. The production capacity can reach 80,000 tons/year of lubricating oil and 20,000 tons/year of antifreeze.
The tank area is divided into five parts: finished additives tank area, basic oil tank area, glycol tank area, integrated plant blending tank area, etc.There are 103 tanks with a total capacity of 29,370 cubic meters.
The comprehensive workshop is composed of sol workshop, production office, laboratory, automatic coordination control office and filling line.The integration of production or production related departments ensures maximum efficiency of production.
There are 19 production lines in the comprehensive plant, including 8 200L VAT filling lines, 4 antifreeze filling lines and 7 lubricating oil filling lines (including 2 OCME production lines). Each production line is connected by an independent pipeline and intersects with the oil pipeline at the universal manifold. The production pipeline at the manifold can be connected with any product pipeline, which greatly saves the time spent on replacing oil products.
The storage center, which adopts three-dimensional storage mode, has 10,560 warehouse locations and can store about 600,000 pieces of various products.
- 170Mu
Total floor area
- 103
Large and small tanks
- 19
Comprehensive plant production lines
- 10560
Automatic warehouse center location
- 600000
Full stock storage products
The tank storage area is divided into five parts: finished additives tank area, basic oil tank area, glycol tank area, integrated plant blending tank area, etc.There are 103 tanks with a total capacity of 29,370 cubic meters.
The total capacity of the raw oil tank area is 4000m?.
The total capacity of the base tank area is 17,000 m?.
The total capacity of additive and refined oil tank area is 5650m?.
Additives are stored in dedicated tank lines to prevent cross-contamination during unloading, storage and feeding that would compromise oil quality. Each tank bottom is fitted with an integrated local heater for staged heating during unloading, eliminating additive performance degradation from repeated heating. All process pipelines feature electric tracing systems to sustain preset temperatures, cutting transport heat loss and boosting blending efficiency. Furthermore, storage tanks adopt metering systems from a world-leading specialist metering firm, supporting high-precision regular level detection, high/low level alarms and real-time tank level data reporting. This ensures accurate daily measurement and real-time inventory monitoring.
PIGGING SYSTEM
In process industries, pigging technology uses specialized pipeline pigs to recover residual liquid inside pipes instead of discarding it. Our pigging system minimizes pipeline residue to just 1 gram per meter.
XP Automatic Ball Manifold
Manifold specifications can be expanded in phases to accommodate project progress. Each inlet and outlet pipeline of the manifold supports custom pigging pipe diameters tailored to production demands. The design enables one inlet to feed multiple outlets, allowing a single material to be simultaneously distributed to multiple filling lines for batch filling.
We deploy top-tier Emerson blending hardware and systems to deliver:
SMB synchronous dosing precision: ±0.1%
BBV rapid blending cycle: 15–25 mins
DDU drum metering accuracy: ±0.1%
Integrated pipeline pigging, manifold and full metering management
Emerson WINBLEND System Seven is a premium process control platform built on 40 years of proprietary blending and flow measurement technology.As an established lubricant industry leader with over four decades of field experience, Emerson delivers proven reliable solutions.
Advantages
High AutomationThe full blending cycle runs automatically per preset programs with no manual operation required.
Superior FlexibilityEach batch can be as low as 10–20% of the blender tank capacity, while mass production is available via multiple batches. The streamlined process supports precise additive dosing via DDU or manually weighed solid additives.
Effective Cross-Contamination ControlBlending and auxiliary metering tanks are polished stainless steel to reduce oil adhesion. Equipped with high-efficiency flush nozzles and self-draining pipelines, the system only needs minimal base oil for product changeover cleaning. The cleaning oil is recycled into the blending tundish as raw material.
Fast Production CycleA standard 10-ton batch of lubricant grease takes just 1 hour to complete blending.
SMB integrates inline pipeline metered blending (ILB) with tank blending logic for highly flexible mixing.Components can be dosed via flowmeters, manual weighing or other feeding methods.
SMB delivers outstanding operational flexibility and easy multi-product switching, with minimal cross-contamination risk. It supports both large and small batch production for diverse product lines.
OCME High-Speed Automatic Filling Line
Imported from Italy, this fully automatic OCME filling line links all stations via photoelectric sensors for high-speed unmanned production. Its compact integrated design cuts floor space, boosts single-unit output and lowers labor expenses. Built-in safety guards, isolation barriers and safety doors fully protect operators and maintenance staff. Deploying this line accelerates our progress toward Industry 4.0.
Its weighing module holds MID certification, with weighing error limited to 0.5‰.
Tank Spraying System
Two spray assemblies inside oil storage tanks wash inner walls during product changeovers to remove residual oil and guarantee consistent product quality.
Pressurization System
The filler features an adjustable pressurization unit matching semi-finished product flow rates to raise filling efficiency. Output hits 12,000 bottles/hour for 1L containers.
OCME Italian High-Speed Automatic Filler
This high-speed filling machine is imported directly from Italy. All line stations are interlocked via photoelectric sensors to enable fully automated high-speed production.
Boasting an exclusive integrated structural design, the OCME filler delivers compact footprint, superior single-unit output and significant labor savings. It is fully fitted with intelligent safety interlocks, isolation barriers and safety doors to maximize operator and maintenance staff protection.
Certified Weighing ModuleCompliant with MID standards, it limits filling tolerance to ≤5‰.
Dual Flushing SystemTwo independent spray nozzles are installed inside the oil reservoir. During product changeovers, tank inner walls are thoroughly rinsed to eliminate cross-contamination from residual oil and guarantee consistent product quality.
Boost Pressure Filling SystemBuilt-in pressurization units adjust pressure dynamically based on semi-finished product flow rates for faster filling throughput.For 1L containers, the machine achieves a production capacity of 12,000 bottles per hour.
The automatic depalletising machine is composed of depalletizing area, pallet unpacking area, product output area, pallet conveyor area, pallet stacker area, product export conveyor area, sandwich extraction car area, etc. Automatic depalletising is realized through the output conveyor.
The rotary weight filler machine can achieve the actual filling speed of 9600~12000 bottles/hour for 1L products and 6000~9000 bottles/hour for 4L products, and ensure the filling accuracy within 2g.
OCME’s automatic case packer is a high-output secondary packaging solution.Prior to packing, an automatic lane divider sorts products into separate tracks. The integrated cardboard magazine feeds blank cartons, enabling fully automated packing and sealing at a rated speed of 65 cartons per minute.
This machine boasts easy operation, low adhesive consumption, outstanding efficiency and reliable safety.Glue-based sealing delivers tidy, aesthetic finished cartons with anti-tampering and anti-leakage performance; the process is clean and eco-friendly.
Once products are sealed by the automatic packer, they pass through labelling and weight recheck stations before being palletized by the palletizer.As the end-of-line equipment matching OCME high-speed filling machines, this palletizer delivers fast, precise and stable pallet loading to keep pace with high-speed production cycles.Beyond fully automatic cyclic operation, operators may manually control the palletizing arm via hand levers or parameter adjustment to match variable production requirements.
This AS/RS system consists of racks, tunnel stacker cranes, loading/unloading platforms, dispatching and management control systems.
It has 10,560 storage slots with a total capacity of 600,000 goods units. Supported by warehouse management software, graphic monitoring, barcode tracking, sorting and stacker control modules as well as position detectors, the system realizes vertical storage, automatic stock access and standardized warehouse management.
