Glue Line - MattressTek

Full Glue Lamination Line

Case Study: Fully Automated Lamination Line

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. They also wanted to minimise space.

We presented our range of machines that meet those needs and found that they could also benefit from:

Loading into line automated to a programmed time sequence
Producing 450+ on each 8-hour shift
The addition of sock closers to the side of the main line, between being filled by the fire sock stuffer and cover stuffer, to prevent delays and reduce slowing down production as this is the element that takes the longest
Label adding before mattresses are rolled and packed for transportation.

This was the 7th line we have installed for this client.

The machines they have include:

CTek Belt-driven Straight Line conveyors, C90 90-degree conveyors, BRotateTek, 2x STFTek Stuffers, 2x SCTek Sock Closers, 1x FlipUpTek (with Rollers) – Fill In/Drop down conveyor, ICONTek Inspection quality control conveyor and 180FlipTek 180 Flip/Rotation conveyor.

How they have been installed, implemented and the impact it has had on production:

95% efficiency
Delivered on-time and within the tight timescales

Working with the operations team, we liaised via video calls to establish their requirements and matched this with a to-scale virtual walk-through of their current line to identify how the machines would fit into the existing line and where they could use other conveyors from our range. Our designers instigated the seamless addition to the line by ensuring minimal space wastage and the placement of multiple machines along the line to speed up various aspects. This assisted the installations for the fitters on-site.