Mattress Machinery
Mattress Making Machines
Conveyors
Full Factory Automation
Case Studies
We have installed our machines as part of full production lines across America, Mexico, Europe, Australia and the UK.
Here are some case studies from full automated processing systems that enable manufacturers and processors to transport components and products across and around factories, logistics centres and fulfillment distribution centres.
Foam Insert Water Jet Line
This water jet line is the second of two production lines aimed at reducing the number of operators, speed up and automate their production – comprising conveyors feeding from de-stackers to water jets and then into stacker.
The second full-scale automation production line for a customer in America, comprising 3 (suction cup) De-Stackers, 14 CTek straight-line belt conveyors, 11 C90 rotation conveyors, a BC90 rotation conveyor and 2 Stacker (one belt conveyed and one vacuum suction units).
Piled layers of foam are de-stacked by one of three De-Stackers to feed into a line of conveyors. They are fed into water jet cutters which cut required shapes of the foam components to be used in the make-up of the inserts of crates. Once cut they move along the conveyor line and onto the next stage.
Crate Build-Up Chain Conveyor Line
This crate build-up line is made up of chain conveyors that feed pallets with foam parts on under a deck using scissor lifts in order for operators to build up the foam parts to create a crate.
This production line transports wooden pallet-style panels that are used to construct crates for the transportation and storage of products.
This solution reduces the headcount of workers, speeds up the process, reduces labour and can be run automatically at the press of a button.
The line was made fully bespoke for a manufacturer who had been awarded a government contract in the US.
We presented our range of machines that meet those needs and found that they could also benefit from automating the line, using a chain conveying system.
MattressTek have the designers, the engineers and the infrastructure to build conveyors to suit the customer’s exact needs. We have in excess of 40 years experience in the industry.
We will design any bespoke conveyor that suits your needs.
This production line incorporates a Hot Glue Bridge, TAMP, Stacker, CATek Centre Aligner and CTek straight-line belt conveyors.
We will design any bespoke conveyor that suits your needs.
The original transportation method to move the mattresses around the facility and production line and down to the lower floor, for loading into logistics, was the use of wooden planks to slide them over a downward staircase with no guided directional guards to reduce injury to operations and damage to the site. This also risked damage to the products themselves too.
The purpose of the line is to feed multiple belt and roller conveyors, from the foam cutting saw, using a shuttle conveyor which runs along a track.
The purpose of the line is to transport foam blocks from saws and carousels around a factory.
Bespoke Foam Handling Conveyor Solution
Bespoke Conveyor Solution for compression of rolled foam buns
The customer came to us to resolve the problem of loading their round rolled foam bun compressing machine.
This production line transports divan bed bases (of various size) from one end of the factory to two inspection tables before being fed into a wrapping machine, manoeuvred by two 90-degree rotations, through a passage around into the storage area where it moves over gravity roller conveyors ready to be lifted onto racking.
This production line transports foam blocks and buns (of various size) across the factory using straight-line belt conveyors, BC90s rotation conveyors.
Mattress Inspection and Auto-Wrapper Feed
This line comprises addition of an ICON Tek belt-driven conveyor before moving on to a C90 Tek multi-directional belt and roller conveyor to manoeuvre it 90 degrees into a wrapping machine.
This production line transports foam blocks and buns (of various size) across the factory using straight-line belt conveyors, BC90s rotation conveyors.
Roll Pack Line
This production line incorporates the inclusion of 4 RollPack machines for ease of rolling beds of pocket springs into paper, to be palletised (4 rolls per pallet) and stored for later use or transport.
The machines that make up this line include:
20x CTek Belt-driven Straight Line conveyors to transport the pocket spring beds to the RollPacks, 5x C90Tek 90 degree rotation conveyors and a FlipUpTek extension.
Mattress Foam Layer De-Stacker Line
This production line transports piles of pre-cut foam blocks, of multiple thickness, from one end of the factory to another to be layered correctly, using a stacker conveyor machine, to build up the internal components of a mattress.
The line comprises a total of 18 straight-line belt driven conveyors, at least four C90 multi-directional conveyors to turn 90 degrees, three De-Stacker machines and a 180FlipTek rotation conveyor that flips 180 degrees, along with a Hot Glue Bridge.
This is an addition to the existing production line that relied on a total of 12 operators who were required to endure monotony, heavy lifting/strain and time wastage as they previously used a forklift truck to transport multiple foam blocks (up to an inch thick, up to 14 inches) stacked 40’ high, from a saw, 30-40 metres across a facility onto a short conveyor line, after flipping them manually ready to be layered to form the interior of a mattress.
This production line incorporates the loading of square foam blocks onto an extension in-feed conveyor to be cut and shaped into round foam sponges.
Long inclined conveyors are then tasked to arrange and sort round sponges into an orderly single file using sponge deflectors.
A sorting machine then pairs the sponges into sets of two and feeds them into the wrapping machine.
Featured Machines
Call a member of our team on 01282 479922 to discuss your specific Mattress Machinery requirements.
Useful Links
MattressTek
Unit 3 Forest Mill
Burnley Road East
Water, Rossendale
Lancashire
BB4 9BF
