Case Study: How Ba Jie Brush Solved a High-Density Bristle Challenge for the UK’s Largest Sealing Products Retailer

At Ba Jie Brush, we are proud to share a recent success story that demonstrates our problem-solving ability and dedication to quality. This case study highlights how our production team helped Mr. D, a representative of the largest sealing products retailer in the UK, overcome a serious challenge with his Clip On Profile Flexible Brush Strip supply.

The Challenge

Mr. D approached us with a clear but difficult problem. His company’s Clip On Profile Flexible Brush Strip was their main selling product. For years, they had sourced it from another manufacturer in Germany, but rising costs made the partnership unsustainable. Searching for alternatives, he explored almost every brush factory in China. Unfortunately, after countless sampling rounds, none could meet his strict quality standards.

His requirements were extremely demanding:

• The flexible rubber profile had to be 9x18mm in size.
• The brush strip needed two rows of bristles.
• Each 100mm length of profile had to contain 61 bristle holes in total.

In short, Mr. D required exceptionally high bristle density combined with durability. He admitted that after so many failed attempts, he was close to giving up.

The Obstacles

When our production team began sampling, we quickly realized the complexity of the task. It was the first time we had encountered such a high-density requirement. The initial trials failed, and we identified two main reasons:

1. When the bristle density was increased to the required level, the bristles became unstable and easily falling off.
2. When the bristles were firmly fixed, the density was below the target.

It seemed impossible to achieve both strength and density simultaneously.

Our Solution

Instead of giving up, our production team treated these failures as valuable insights. Step by step, we developed a new approach:

1. Optimizing the Flexible Profile – We tested multiple grades of flexible rubber, aiming for the right balance between hardness and elasticity. After several trials, we identified the perfect middle ground: a material firm enough to hold the bristles securely, yet soft enough to maintain flexibility.
2. Upgrading the Planting Machine – We improved our tufting process by adjusting the planting equipment. This modification allowed the bristles to be anchored deeper and more securely within the profile, ensuring both density and durability.

With these adjustments, we conducted four internal test rounds. On the fourth attempt, we finally succeeded in producing a Clip On Profile Flexible Brush Strip that fully met Mr. D’s specifications.

The Results

When Mr. D received the samples, his response was enthusiastic. He commented:

“Ba Jie Brush has delivered German-level quality at a much more competitive price. This not only saves us significant costs but also strengthens our competitive advantage in the local market.”

He went on to call us “the best Flexible Brush Strip manufacturer in China, with a true spirit of perseverance and co-development.”

Conclusion

This case reflects the strength of Ba Jie Brush:

• Commitment to solving customer challenges
• Ability to innovate in production processes
• Dedication to achieving world-class quality at competitive prices

Through close collaboration and relentless problem-solving, we helped Mr. D secure a more cost-effective supply chain without compromising on performance.

A Ba Jie Brush, we believe every challenge is an opportunity to innovate.