A mattress is made up of different layers of material and filling. This contributes to the comfort and benefits of the sleep experience. Obviously there’s foam and springs and fabric but how is a quality mattress actually made?

 

How It’s Made?

 

Every product that exists has to be made, but before that can happen it needs to be designed. The same goes for the machines that help in the smooth running of the making (or manufacturing) process. That’s where we come in.

 

With a combined wealth of knowledge and experience spanning over 40 years, we are leaders in the manufacturing of machines for the industry that makes mattresses so here’s a spring-by-spring, hop-along guide to what goes into making a mattress and what machines are used to ensure efficiency, the saving of time and robustness of the mattresses made by our customers.

 

With a full automation service available, our machines and conveyors mean that more mattresses can be made and sold, and therefore more people can healthily relax and enjoy the benefits of a quality mattress.

 

So, first of all our experienced CAD (Computer-Aided Design) designers create a virtual model drawing of the product, based on the brief, specification and specific requirements and needs of our customers, for our engineers to then work from when constructing the various machines. Following the process of how a mattress itself is constructed, we offer a whole host of machines that service more specific purposes.

 

First up in the making of a mattress are the various layers of foam and other materials that ensure that the product is comfortable for the user, as well as the springs. These layers need to be cut to meet the various measurements of the bed size and dimensions. The cover over the layers, sometimes called the sock or ticking, keeps the insides of the mattress together and also provides a layer of protection. The top and sides also can also be quilted.

 

Machines like our RSTek Roll Slitter, BCuttTek Border Cutter, VBTek Vertical Border Cutter, VP Vertical Panel Cutter and HMTek Handle and Label Maker automatically cut components, with a 3DTek stitching designs and the SergeTek Double Overlocker securing the panels in order for the TampTek to press it all together once it has passed onto the Hot Glue Bridge which applies glue to the layers to keep them together. Our CATek Centre Aligner ensures that it is in the right position for accurate layering.

 

Once the layers are piled, glued and pressed together, the cover can be constructed using the machine-cut panels and borders to be attached using a HLATek Handle and Label Attaching sewing machine, TakTek Side Stitch Tacker, SCTek Sock Closer, SSTek Side Stitch Table and TapeTek Tape Edger before the STFTek Stuffer fills the cover with the layered mattress filling. Tufting can then be done with our TUFTTek.

 

They can then be stacked using the StackerTek after being transported around the factory using a CTek, CITek, GravTek Gravity Roller and rotation conveyors like RotateTek, BRotateTek and BC90, C90Tek or Bun Pusher. In the interest of quality control, inspection conveyors, flipping and turning tables are also available – FlipUpTek, 180FlipTek and ICONTek. Our BridgeTek can also split a conveyor and flip the two halves to vertical position to create a walkway.

 

Some providers leave gaps in the chain and this means that production creates a bottle-neck which can sometimes delay and even halt operations. We are different. We expertly find solutions to prevent these delays occurring and these have proven extremely effective and popular with grateful customers. Some examples of these solutions will soon be available.

 

We can also design and make bespoke machines for existing production lines and these will fit seamlessly (pun intended) into the automation of conveyors to reduce the loss of time, whilst also having a keen focus on health and safety to allow minimal lifting whist turning, flipping and rotating materials and the finished product.

Machines like our UBTek Spring Unbaler, inspection and flip conveyors reduce the labour strain of unpacking, lifting and turning mattresses.