This line involved the processing of 60ft foam blocks being loaded at the start of the line (shown at the top of the image), to be cut down to lengths of around 8ft. The foam operator decides which conveyor line the foam blocks take. Between two processing lines including a carousel cutter to trim them into thinner layers for mattress manufacturing and the next stage of a process.

There was a desire to reduce labour of, and by, operators along the production line, as well as increasing capacity and speeding up production, whilst ensuring minimal health and safety risks and damage to both the product components and machines. They also wanted to make best use space.

We presented our range of machines that meet those needs and found that they could also benefit from automating most of the line and including machines to rotate foam blocks around, between and feeding into, saws and cutting machines, carousels and convoluter.

The machines they have include:

CTek Belt-driven Straight-line conveyors, Heavy Duty Straight-line Incline conveyors, BC90 90-degree conveyors and GRAVTek Gravity Roller conveyors.