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Internal Cover The Global Systems Group of Leggett & Platt Inc., based in Carthage, Missouri, has launched the Nähtec NC1200 zipper sewing station, which provides zipper covers on the inside.
From May 5th to 8th, in the entire machinery exhibition hall of Interzum in Cologne, Germany, exhibitors paid great attention to speed and automation, which is a solution to the rising global labor cost. In order to meet the needs of large mattress manufacturers operating in the integrated market, machinery suppliers have provided efficiency improvements and more options to assemble the entire production line. Many introductions focused on helping mattress manufacturers bring the production process into the interior while simplifying or "lowering the skill" of mechanical operations.
As in past exhibitions, mattress manufacturers have purchased multi-functional frame equipment, and this year they have also purchased rolling machines. In fact, at this exhibition, the surge of compression and packaging equipment to meet the rapidly growing demand for e-commerce is not to be missed.
The Mammut P2A of E. Stutznäcker GmbH & Co. KG, headquartered in Cologne, Germany, is a double-head, single-needle, lockstitch quilting machine for producing complex designs on mattress panels.
Speed is the core focus of quilting machinery supplier Meca Srl. Its headquarters is located in Olona, Italy. The company is equipped with a new 100-inch multi-needle quilting machine Inventio, known as "the fastest quilting machine in the world" . Inventio was originally launched at the ISPA Expo in 2013. With a width of 50 inches, Inventio quilted panels and bezels directly from rolls of material instead of pre-cut strips. The Inventio quilting machine uses a fully integrated Pegasus computer control system. According to its tagline, Meca's new Target Nextra multi-needle double-chain stitch quilting machine operates at 1,600 rpm, which is “faster than the speed of light”. Meca manufactures and sells eight Italian-made quilting machines and recently signed an agreement to grant Atlanta Attachment Co. Inc. exclusive distribution rights in North America.
Tufting makes it easy. The MPT Group, headquartered in Lancashire, England, demonstrated the new Auto-Tuft, a fully automatic system capable of tufting up to 250 mattresses in an 8-hour shift.
Global Systems Group, the mechanical division of Leggett & Platt Inc., showcased more than 50 machines and work aids at the show, and launched the "technology package" Wildstitch for Gribetz V-16 and the new Paragon quilting machine to speed things up , The increase in quilting increases the throughput by 25% without putting pressure on the machine.
Jurgen Van Osch, assistant service manager at Atlanta Attachment Co. Inc. in Lawrenceville, Georgia, showed off a semi-automatic universal two-handle machine designed to provide small and medium manufacturers with flexibility.
The Carthage, Missouri-based company also showcased the new Porter EST-501 automatic flange machine, which is an electric belt table to improve the efficiency of flange operations. It is equipped with a powerful PFM-4000 flanger.
Paul Block, Vice President of International Sales/Sales Strategy/Product Planning, GSG Asia Pacific, said: “This is one of our most popular machines at the moment-it eliminates the skills of flanging operations, while increasing productivity and improving product quality and Consistency." "EST-501 is designed to flange the thickest and densest mattress panels in the industry. It eliminates non-value-added labor and allows operators to train and run the machine within a few days."
GSG also announced a new partnership with Eton Systems, a Swedish company headquartered in Alpharetta, Georgia. The company specializes in helping manufacturers reduce indirect labor by eliminating waste disposal of materials on the production floor and improving single-piece production processes. GSG is integrating its system with Eton's to create a work cell that combines the technology and machinery of the two companies. For example, after the panel passes through the quilting machine and panel cutting machine, the Eton system can automatically pick it up and transport it to the flanging machine.
FillMatic GmbH, a machinery supplier based in Mannheim, Germany, uses a miniature "toy shop" model of its wide range of products, including automated processing and transportation modules for the mattress production line. Sales director Erich Rudolf said that the company designs and equips entire mattress manufacturing plants for major manufacturers around the world.
Versatility The Inventio multi-needle quilting machine is suitable for frames and panels in Olona, Italy, and is now available in 50-inch and 100-inch working widths. The machine saves production steps and provides improved quilt patterns and versatility.
E. Stutznäcker GmbH & Co. KG, headquartered in Cologne, Germany, will focus on the new prototype of Mammut P2A, which is a double-headed, single-needle, overlock quilting machine.
"Manufacturers need single needles because they are interested in higher precision quilt designs," said managing director Nikolaus Fremery. "Although the output is lower (compared to the multi-needle machine), you can get a higher artistry and a higher style bedding appearance."
In addition, the company stated that its Mammut VMK chain multi-needle quilting machine is now faster than ever. "It's not just that the quilting operation has speeded up, the whole machine runs faster. The manufacturer is pairing it with the Mammut MPS 250 mattress hemming system and Stacker," Fremery said. "This is a powerful three-part system that can generate higher productivity and can run 24/7."
Speed and innovation are the top considerations for the Bursa-based company Elektroteks, which has quilting, frame and packaging machines, and a mattress production line. The company lists its KYK-S automatic tape edge banding machine as "super fast", capable of producing 200 to 250 mattresses in an 8-hour shift. The company describes its Falcon quilting machine as the "fastest quilting machine" in panel design, with a continuous roller feed system.
Elektroteks' sales have increased tenfold in the past five years, exporting to 65 countries, said Serkan Guler, director of international sales.
The do-it-yourself Maquinol Intelligent Machinery in Estareja, Portugal has launched a new Colmat Exacto foam core production line for small manufacturers.
GSG’s Block said: “Allowing manufacturers to introduce production processes (the processes they previously sent to processors) into in-house equipment is becoming more and more important because it enables mattress manufacturers to better control costs, inventory, and inventory. Products."
The equipment innovations used to sew complex bedsides have been eye-catching at the recent equipment show and continue to shine at Interzum Cologne. Atlanta Attachment demonstrated its new semi-automatic universal dual-handle machine, which is characterized by the ability to adjust the nailer to produce vertical or horizontal handles of different lengths. The two heads can be locked in place and fixed both ends of the handle at the same time, and can be repositioned at the press of a button.
No need to cut by hand anymore. Global Systems Group of Leggett & Platt Inc., based in Carthage, Missouri, has added Porter International ZipCutter for automatic sewing cover production.
"It provides some flexibility for small and medium manufacturers," said Hanklett, the president. "We have received a lot of requests for things that are not fully automated and flexible."
Atlanta Attachment also introduced a quilting repair machine with under-bed thread trimming controlled by an automatic presser foot. Little said that this servo-driven machine is particularly useful when dealing with large panels.
But what Little talked about most at Interzum was the company's new partnership with Meca Srl and Aper Srl in Bologna, Italy.
Aerial view FillMatic GmbH, headquartered in Mannheim, Germany, uses miniature models to demonstrate its production line capabilities, from glue coating to roll packaging.
"We are increasing our international staff and international influence," Little said. "We only represent Meca in North America, and Aper in North America, Australia and New Zealand. I call this a strategic alliance."
With its Gribetz Strata, GSG meets the growing demand for internal material lamination, which adheres FR material, foam or fiber to the frame or tick roll of the panel. Strata uses easy-to-control dry adhesive handling and can handle materials up to 90 inches wide. The company also launched Porter International ZipCutter, an economical flat product cutter that helps in-house sewn cover production while eliminating labor-intensive manual cutting. ZipCutter has a computer-controlled rotary cutter, which has all-round cutting capabilities. Similarly, GSG’s Nähtec NC1200 zipper sewing station uses hidden zippers to effectively connect two mattress covers, providing mattress manufacturers with internal zipper covers. The sewing station is located in the center of the machine for easy operation.
Maquinol Intelligent Machinery, located in Estareja, Portugal, has launched Colmat Exacto, a foam core production line that allows smaller manufacturers to mix and pour their own mattress cores of various specifications.
Maquinol Sales Manager Sumya Diaz said: "The system runs through a touch screen panel and uses Dow Chemical products, which cures quickly and is not sticky." "We recommend that you buy six molds for the system. Others provide injection systems. , But the price is higher, ours is not wasted. This is a small production line that allows you to adjust the density of the foam to obtain a high-end, latex-like foam feel."
The new Lamit Twinglue from Albrecht Bäumer GmbH & Co., a two-in-one foam cutting machine manufacturer, has a multi-purpose adhesive function and has attracted many German companies' exhibition spaces.
GSG launched the Gateway GS-19E hot melt glue system, a glue bridge equipped with multiple fixed and mobile glue guns. The machine is part of a flexible automation system that can be set up in different configurations to create foam-wrapped accumulations or laminated foam layers.
Lamit, a bonding machine specialist based in Wesel, Germany, was acquired by Albrecht Bäumer GmbH & Co. to launch an innovative adhesive application system that combines two bonding processes in one machine. According to the company, with Lamit Twinglue, mattress manufacturers no longer need to choose between water-based dispersions or hot-melt adhesives.
Another new product from Bäumer is the automatic multifunctional table, which can be added to the existing base of the Bäumer horizontal contour cutting machine to separate the foam blocks. Harald Kullmann, Bäumer's sales director, stated that the watch has "excellent accuracy and higher operating speed."
FillMatic launched the SRA gluing machine, which uses Simalfa 315 OF water-based adhesive for cost-effective mattress production.
This machine "completes our capabilities and is designed for unique mattress experts who build complex beds, who used to apply glue by hand," Rudolf said. The sturdy and durable SRA has a conveyor with a silicone belt, a press with an automatic height recognition function, an adjustable compression amount and can be adapted to existing production lines.
According to the company, the average edge banding time of Elektroteks' new FixET automatic hot melt adhesive production line is 20 seconds.
The basic winding machine Dolphin Pack's new Ander Roll B winding machine, headquartered in Affi, Italy, is a simplified version of a small batch manufacturer.
Roll charter to the rescue
Mattress manufacturers looking for compression and rolling equipment at Interzum Cologne have many options. The capacity and speed of the machines, the way they handle the compression and folding process, and whether they are used with built-in spring beds vary. The latest machines can add plastic film outer packaging to the compressed and rolled bed to provide more protection during transportation and handling.
Rolling forward in Montemuro, Italy's Gruppo Grassi offers Variomatic Plus, a compression and reel packaging machine with side and front exhaust.
The GSG Teknomac TK381/1 package system with automatic packaging and compression and coiling technology is not new, but it is significantly faster. "It is now an important part of the business," Brock said. The high-speed unit can compress and roll foam or built-in spring mattresses when needed-up to three pieces per minute. It also allows the operator to adjust the size of the reel.
Block said that another GSG machine, the Merello ME105 mattress packaging machine, is “the fastest packaging machine in the mattress industry” and can pack up to 5 units per minute. It automatically adjusts to accept different unit sizes and has reliable cold sealing technology.
Sala Macchine Speciali Srl is headquartered in Sereno, Italy, and provides faster, conveyor-based packaging and reel production lines.
The FillMatic RollPack, launched in 1996, "is very popular now," Rudolph said. The machine uses plastic film to flat pack or roll mattresses at a rate of one sheet every 12 to 30 seconds.
Gruppo Grassi, located in Montemuro, Italy, provides a full range of mattress machinery. The company said that sales of its rolling equipment are very active.
“We sold six-roll packages in two days,” said Gianroberto Cioni, chief financial officer and export manager. "Our machines are getting faster and more powerful, and on the whole, its automatic cycles can remove workers from the process and reduce production time."
The company's top-of-the-line Line Vacuum Mattress system can roll and pack four mattresses per minute. Another Gruppo Grassi packaging machine, Variomatic Plus, has two exhaust ports for coordination with automated production lines or manually. It is suitable for foam and built-in spring beds, and additional polyethylene outer packaging will be applied.
Dolphin Pack, headquartered in Affi, Italy, showcased its full range of packaging equipment, including the new Ander Roll R rolling device, and the new Mistral 3B MT Basic bagging machine for all mattress sizes.
US sales manager Cris Verselloni said that these two new devices are simpler versions of Dolphin Pack's premier bagging and rolling machines, and are aimed at small-volume manufacturers and areas where labor costs are not an increasing concern.
Mario Sala, head of Sala Macchine Speciali Srl in Serengo, Italy, said that many major American bed manufacturers stopped to see the company's Italian-made packaging and rolling machines. Sala said that when it was first introduced in the 1980s, both types have been improved. The press uses a conveyor instead of a roller, and the equipment can be adjusted according to the final diameter of the mattress. If necessary, the machine will apply the final film on the roller bed. The roller press can accommodate foam and inner spring beds, and can compress and roll a bed every 20 seconds.
Fast and simple is the theme of the new product launched by Macau Taihe Machinery Co., Ltd. for mattress manufacturers who wish to produce their own pocket springs. According to sales director Nelson Wu, the Macau-based company's improved high-speed pocket spring coiler can produce 100 springs per minute, and its high-speed pocket spring assembly machine can be partitioned by wire, nesting, or spring diameter. . Both machines provide greater consistency.
"For current buyers, simplicity makes a lot of sense," Wu said. "We provide efficiency for mattress manufacturers."
MPT Group, a machinery supplier in Lancashire, UK, demonstrated its improved Infinity Sleep Support System, a continuous wire spring unit manufacturer that can now produce units up to 7 3/4 inches, which can be better adapted The contours of the body, said Andrew Trickett, managing director.
MPT also launched the new Auto-Tuft, a fully automatic mattress tufting system capable of tufting up to 250 mattresses in an 8-hour shift. Trickett said that the machine requires only one operator, almost no material handling, and has horizontal feeds for all spring types.
The star product displayed by Jumpsource, a machine parts supplier based in Beverly, Massachusetts, is the company's knotted wheel replacement parts designed for spring making machines. According to Sam Porter, vice president of operations, this is a small and expensive component that many customers require.
Simple and easy to use Brighi Tecnologie Italia headquartered in Forlimpopoli, Italy's fully automatic pillow manufacturing and packaging machine can fill, sew, compress and vacuum seal pillows within a fast burning time.
At Interzum Cologne, Brighi Tecnologie Italia launched several unique machine production lines aimed at improving pillow manufacturing and packaging processes.
The company's export sales manager Matteo Tagliaferri said: "We need more automation and products to provide more accurate details." The company is headquartered in Forlimpopoli, Italy. "Our customers pay more attention to product quality at every stage of manufacturing."
Tagliaferri said that the new Perfect Fill Line has a "100% accurate pre-weighing silo and filling station" that can be used to blow pillows and any filling. Combined with Brighi's new Easy Blow Line and its flagship Easy Pillow and Easy Bag production lines, "We can handle the entire process, basically from the original fiber bag or down bag to the packing pillow in the box, without manual intervention," he said.
Zoom in on Stephen Anstey of XSENSOR Technology Corp. in Calgary, Alberta, showing a screen update of the company's pressure mapping software.
XSENSOR Technology Corp. launched a new feature of pressure imaging software specifically for consumers in Asia and Europe in the first personal showroom of Interzum Cologne.
"It makes the interpretation of the results easier to see and understand," said Stephen Ansti, vice president of international business development. "We found that customers outside of North America have a low level of trust in technology, and they want to know more about the'why' and'how.' You don’t need to know a lot of pressure graphs to understand."
The Calgary, Alberta-based company has also added a feature that can combine the results of couples' stress mapping so they can choose a bed that suits both parties.
(Introduction) Machinery manufacturers launch innovations, and component suppliers focus on airflow, gel and phase change craze
(You are here) Swing "roll" in the machine hall
Art and technology meet in a ticking showroom
Trends in springs, foam and latex
Combine them with adhesive
Sleep Products Industry Business Magazine
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