Hybrid Line - MattressTek

Hot Melt (Hybrid) Spring Layer Automation Mattress Production Line

Case Study: Hybrid 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 streamlining the whole line with programmed automating, with the only operator input being the feeding of foam layers onto the belt-driven straight-line conveyors ready to be sprayed with hot glue, layered on the Hot Glue Bridge, pressed by the TAMPTek before Centre Alignment and being stacked ready for an operator to move the pallet.

The machines they have include:

CTek Belt-driven Straight Line conveyors, Hot Glue Bridge, TAMPTek and Stacker.

Working with the management and 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 and enabled seamless addition to their space, making the process and usage of space more efficient. The addition of the machines to do multiple functions of the process, meant that it was accurate, sped up and increased the amount of layered mattresses produced.