Manufacturing | Ryuzen Automotive Industry Ltd.

Our Facility

Advanced Production Facility

Located in Mirpur Industrial Area, Dhaka, our 15,000+ sq. ft. production facility is purpose-built for brake pad manufacturing. The plant incorporates dedicated zones for raw material storage, mixing, pressing, heat treatment, finishing, and quality inspection.

Our machinery was carefully selected from leading suppliers in China, Taiwan, and Europe — each machine chosen for its reliability, precision, and suitability for brake friction material production.

15,000+

sq.ft. Facility

12

Heavy Machines

6

Production Stages

100%

Quality Inspected

How It's Made

6-Stage Production Process

Every Ryuzen brake pad goes through a meticulously controlled six-stage manufacturing process before it earns our quality clearance.

01

Raw Material Sourcing & Verification

We import premium friction materials — including copper fiber, steel wool, resin, barium sulphate, and friction modifiers — from certified suppliers in China and other global markets. Every batch is tested upon arrival for purity, particle size, and compliance before entering production.

02

Friction Material Mixing

Multiple raw ingredients are precisely weighed and combined in industrial mixers according to our proprietary formulas. The mixing process ensures a homogeneous distribution of all components — critical for uniform friction performance across every brake application.

03

Steel Backing Plate Preparation

Steel backing plates are cleaned, shot-blasted, and coated with a bonding primer. Each plate is dimensionally inspected to ensure perfect fitment. The adhesive layer is critical for the long-term bond between the steel backing and friction compound under extreme braking forces.

04

Hot Press Molding

The friction mixture and prepared backing plate are loaded into our high-tonnage hydraulic hot press machines. Under controlled temperature (150–200°C) and pressure (200–400 tons), the friction material cures and bonds permanently to the backing plate, forming a dense, uniform pad.

05

Heat Treatment (Curing Oven)

Post-press, brake pads are transferred to programmable curing ovens where they undergo a controlled heat treatment cycle at temperatures up to 250°C. This curing process drives out volatile organic compounds, completes the resin crosslinking, and stabilizes the friction coefficient — eliminating fade on first use.

06

Grinding, Surface Finishing & Final QC

Pads are precision ground to exact thickness tolerances, edges chamfered, and wear indicator slots machined. Each pad is then measured, visually inspected, and tested for hardness, dimensions, and friction surface quality before packaging and dispatch.

Key Equipment

High-Tonnage Hydraulic Hot Press
Programmable Curing Ovens (3 units)
Industrial Friction Material Mixers
CNC Surface Grinder & Chamfering Machine
Shot Blasting Machine (Steel Prep)
Hardness Tester & Dimension Inspector

Our Equipment

Heavy Machinery

Hydraulic Hot Press Machine

200-ton hydraulic press with programmable temperature control for precise hot-molding of friction compounds onto steel backing plates.

Programmable Curing Oven

Industrial-grade convection oven with programmable heat profiles up to 300°C — critical for full resin cure and outgassing of volatile compounds.

CNC Surface Grinder

Computer-controlled precision surface grinder for achieving exact pad thickness tolerances of ±0.05mm — ensuring perfect disc clearance and smooth bedding.

Friction Material Mixer

High-shear industrial mixer for homogeneous blending of multi-component friction formulations — ensuring consistent material properties batch to batch.

Shot Blasting System

Automated steel shot blaster that prepares backing plates by removing mill scale and creating the micro-rough surface profile needed for optimal adhesive bonding.

Quality Inspection Station

Multi-point quality station with Rockwell hardness tester, digital caliper measurement system, and visual inspection rigs for 100% final product verification.

Global Sourcing

Raw Materials & Supply Chain

Quality brake pads start with quality raw materials. We source our friction compounds from certified international suppliers, ensuring consistency and high performance in every pad we produce.

China — Primary Supplier

Steel wool, copper fibers, barium sulphate, friction modifiers, resin phenolic binders sourced from certified Chinese factories.

Friction Modifiers

Graphite, vermiculite, cashew friction dust, and aramid fiber for thermal stability and noise reduction — sourced to exact technical specifications.

Steel Backing Plates

High-tensile stamped steel backing plates precision-manufactured to OEM specifications with anti-corrosion coating for long-term durability.

Phenolic Resin Binders

High-temperature phenolic resin acts as the matrix binder, providing structural integrity to the pad while maintaining stable friction at elevated temperatures.

Import & Logistics

All raw materials are imported via Chittagong Port with complete documentation, batch certification, and in-bound quality inspection before entering production.

Storage & Inventory

Climate-controlled raw material storage ensures materials remain within specification. FIFO inventory management prevents degradation from extended storage.

Zero Defect Policy

Quality Control

Quality at Ryuzen is not an afterthought — it is embedded in every step of our manufacturing process. Our multi-layer QC system catches issues early and eliminates defects before they reach the customer.

Incoming QC

Every raw material batch is tested for composition, particle size, moisture content, and compliance before acceptance.

In-Process QC

Pressing temperatures, pressures, and curing profiles are continuously monitored. First-off piece inspection at every stage change.

Dimensional Check

100% dimensional inspection after grinding — thickness, length, width, and chamfer tolerances checked to ±0.05mm using digital gauges.

Final Release QC

Hardness testing, visual inspection, paint/coating check, and batch traceability documentation before each product is cleared for packaging.

Our Manufacturing

Advanced Production Facility