Our hair foil production line
Hair Foil Factory converts aluminium foil into hair foil on 2 production lines in Shangrao, with a monthly capacity of 100,000 boxes. The foil passes through six steps in the plant: slitting, embossing, cutting or folding, boxing, inspection and carton packing. Each step is shown below with the equipment that performs it.
From foil coil to boxed sheets
Hair foil is made by converting a wide coil of aluminium foil. The steps run in this order.
- Slitting. The master coil is slit into narrow rolls at the width of the finished foil.
- Embossing. For embossed foil, the strip passes between patterned rollers that press the texture into it.
- Cutting or folding. Rolls are rewound to their finished length. Sheets are cut to length; pop-up sheets are cut and interfolded in one stack.
- Boxing. Sheets are counted into boxes, and rolls are packed in cutter boxes or sleeves.
- Inspection. Samples from the run are checked against the specification before the lot is released.
- Carton packing. Boxes are packed into export cartons and marked.
Equipment
Every machine on the line is our own. Each step below runs in the plant, not at a subcontractor.
| Equipment | What it does | In-house |
|---|---|---|
| Slitter | Slits the master coil to the finished width | Yes |
| Embossing unit | Presses the emboss pattern into the foil | Yes |
| Sheet cutter | Cuts sheets to length | Yes |
| Interfolder | Cuts and interfolds pop-up sheets in one stack | Yes |
| Rewinder | Rewinds rolls to their finished length | Yes |
| Boxing | Counts sheets into boxes and packs rolls | Yes |
| Foil printing press | Prints patterns and logos on the foil by gravure | Yes |
The sheet cutter is set up for 5 × 11 in (127 × 279 mm), our main size. Other sheet sizes need a new cutting die or the machine re-set; neither is charged once the order quantity is confirmed.
The measuring and test equipment is listed separately on the quality lab and inspection gates page.
Capacity and lead time
The hair foil line runs 2 production lines with a monthly capacity of 100,000 boxes. An order takes 15–20 days from order to dispatch, every step included, and no more than 25–30 days.
Lead time is not capacity divided by order size. A custom order waits for its plates and its sample before it reaches the line, and a printed order waits for its print run. The hair foil order timeline adds the stages together, and MOQ and lead time by format gives the figures for each format.
Why the line is flexible
The slitter, the embossing unit, the cutter, the interfolder and the rewinder are our own, so a new size, count or roll length is a set-up on our line, not an order placed with a subcontractor. That is why a new cutting die or re-set is free once the order quantity is confirmed, why a stock pop-up order starts at 100 boxes, and why stock samples go out in 1–3 days. Everything that can be set, with its range, is on custom and private label hair foil.
What we don’t do in-house
We do not make everything that goes into a finished box. Any step that is bought in is named here, so that you know who makes each part of your order.
| Item | Made by |
|---|---|
| Aluminium foil coil | In-house |
| Printing on foil | In-house |
| Printing plates | A specialist plate maker |
| Printed boxes | A carton converter |
Visit the factory
The plant is at Building 46, International Furniture City, Sanqingshan West Avenue, Guangxin District, Shangrao City, Jiangxi Province. Visits are arranged by appointment: send your dates with a quote request. If you cannot travel, ask for photographs or video of the line, or of your own order in production.
FAQ
How much hair foil can the factory produce per month?
The Hair Foil Factory line produces 100,000 boxes per month on 2 production lines. Capacity is shared between stock sizes and custom orders, so the lead time for an order depends on the size of the run and on what is already scheduled.
Which steps are done in-house?
Slitting, embossing, cutting, interfolding, boxing, inspection and carton packing are done in the Hair Foil Factory plant. The section "What we don't do in-house" on the factory page names any step that is bought in, so that you know who makes each part of your order.
Can you run a custom size without new tooling?
Hair Foil Factory's sheet line is set up for 5 × 11 in (127 × 279 mm). Other sizes need a new cutting die or the machine re-set, and neither is charged once the order quantity is confirmed. A new emboss pattern needs its own roller, made in 1 month.
Can I see my order in production?
Yes. Hair Foil Factory sends photographs or video of an order on the line on request, and buyers or their inspectors can attend production by appointment. Third-party inspection before shipment can be booked through your own inspection company.