Foam Block Mattress De-Stack Line

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.

The machines they have include:

18 CTek Belt-driven Straight Line conveyors to transport foam layers of varying thickness, four C90Tek 90 degree rotation conveyors, a Hot Glue Bridge and three De-Stackers.

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 better utilisation of space.

We presented our range of machines that meet those needs and found that they could also benefit from automating the line.

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.