For many years tufted mattress have accounted for a large percentage of mattresses sold in the U.K. market. The method of tufting is regarded as one of the most time consuming operations in the mattress manufacturing process and one of the most labour intensive with most companies employing two operatives per tufting machine. The production output from a two-man team is
between 70 – 100 mattress per 8-hour shift, resulting in large producers of tufted products employing up to eight people to obtain 400- tufted mattress per day.
The AUTO-TUFT is a fully automated mattress tufting system and capable of tufting in excess of 200 mattresses per 8 –hour shift. It requires only one operator, virtually eliminating the need for material handling.
Products are introduced into the machine via a horizontal conveyor that centralises the mattress before tufting. Sensors automatically detect the size of the mattress during the in-feed process and relays this data to the AUTO-TUFT’s PLC this then selects the correct tuft pattern for that product size. After tufting is complete, products can either be exited via a gravity conveyor or fed directly into a mattress wrapper.
|Autotuft Technical Specifications|
|Machine speeds based on first to last tuft: 3ft in 85 seconds 4’6” – 5’ in 105 seconds. Production environment data.|
|Plc control using touch screen technology.|
|Horizontal feed suitable for all spring types including pocket units, latex and futon mattresses.|
|Helical avoidance system.|
|Automatic product sizing *optional.|
|Continuous role feed tufts and washers available in full range of sizes.|
|5000 tufts per roll and 1900 washers per roll ensure continuous production of 80 – 100 mattresses without the need for downtime.|
|Fast change over times between different tuft lengths.|
|Caddie system for varying tuft lengths.|
|Video monitoring system *optional.|
|Auto stops for tuft and washer replenishment.|
|Processes product sizes up to: width 2’6" – 7’0" and length up to 7’ *standard machine. Other machine sizes available.<|
|Eliminates RSI disorders.|
|200 + mattresses per 8 hour shift.|
|Reduced material handling.|
|Impressive pay back time on investment.|