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(A well-known plastic enterprise in Japan), specializing in the production of plastic components for home appliances, supplies refrigerator and washing machine shells and internal components to well-known brands, with an annual production capacity of over 50 million pieces.
When the customer was developing yellow panel components for the new energy-saving refrigerator, they faced two core challenges: First, the existing pigments had insufficient heat resistance, and color changes occurred during the 200℃ injection molding process, with a product defect rate as high as 8%. Second, the color saturation is insufficient, and the color difference between batches is obvious, which cannot meet the strict requirements of the Japanese market for the appearance of household appliances.
Business impact: The high defect rate leads to a monthly loss of 1.5 million yen in raw material costs. Unstable color affects the product launch schedule and misses the peak season for home appliance sales. Failure to meet environmental protection standards may lead to product removal from shelves and damage to the brand's reputation.
Customized Solutions and Collaboration Processes
The customer's reason for choice: The customer learned about Tianhuibao through an industry exhibition. After sample testing and factory visits, they reached a cooperation agreement. Core recognition: First, the product has a heat resistance temperature of up to 200℃, which fully matches its injection molding process. Second, it supports precise color customization and stable color difference control.
Solution Overview: We have tailored heat-resistant iron oxide yellow pigment 313 for our customer, specifically addressing their pain points
Optimize the pigment to enhance heat stability and ensure no discoloration after processing at 200℃.
By adopting high-precision color matching technology and through three sample adjustments, it accurately matches the customer's target color number. Provide third-party authoritative environmental protection test reports, clearly indicating that the content of heavy metals and harmful substances is far lower than the Japanese standards.
Implementation Collaboration: Provide 10 sample tests at the initial stage of the project and continuously optimize the formula based on customer feedback. During the mass production stage, 200 tons of products will be delivered in three batches, with each batch accompanied by a test report. During the after-sales stage, Japanese technical advisors are arranged to respond to technical questions 7×24 hours a day.
Quality improvement: The product defect rate has dropped from 8% to 0.5%, reducing raw material waste by 1.5 million yen per month.
Efficiency optimization: The consistency of color batches has been improved. There is no need to frequently adjust the process during production, and the production efficiency has increased by 20%.
Market revenue: The new refrigerator, with its unique and stable yellow appearance, saw a 30% increase in monthly sales after its launch and became a bestseller.
Intangible benefits: The customer has consolidated its cooperative relationship with other customers through this product, increased its market share by 5%, and signed a three-year long-term supply agreement with Tianhuibao, with an annual cooperation amount exceeding 800,000 euros.
Tian Huibao's customized iron oxide yellow pigment has perfectly solved our process and quality problems. Their technical team accurately captured our needs. The heat resistance and color stability of the product far exceeded expectations, helping our new refrigerator stand out in the market. Professional service and reliable quality make them indispensable partners of ours. -- Yuki Tanaka, R&D Director.
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