Case: Serving a leading mattress enterprise in Shandong - CNC Sponge Continuous Line + Automatic Horizontal Foaming Machine solve the dual bottlenecks of \"mattress core quality and production capacity\".

Customer Background

A mattress manufacturing enterprise in Shandong (annual capacity of 300,000 mattresses), specializing in mid-to-high-end latex + sponge composite mattresses. Traditional production relied on \"batch foaming machines + manual cutting\", facing three core problems:

1. Unstable core quality: Sponge density deviation reached ±15kg/m³ (industry standard ±5kg/m³), uneven mattress softness/hardness, customer complaint rate 12%;

2. Low production efficiency: Batch foaming machine single成型 cycle 45 minutes, daily output only 80 mattress cores, unable to match peak season orders (daily requirement 150 cores);

3. High labor cost: Required 10 people per shift to operate foaming machine, cutting, handling, labor cost accounting for 30%.

Aipake Solution

Addressing customer needs, provided an integrated \"CNC Sponge Continuous Production Line + Automatic Horizontal Foaming Machine\" solution, core equipment being:

AP-CNC series CNC Sponge Continuous Production Line: Integrated automatic feeding, CNC metering, continuous foaming, online thickness measurement functions, supporting 24-hour uninterrupted production;

ZH-W series Automatic Horizontal Foaming Machine (10m long mold): Horizontal structure + multi-component synchronous injection technology, solving the \"density不均 caused by gravity settlement in traditional vertical foaming\" problem.

Technical Implementation Details

1. Precise CNC control, solving density deviation:

The production line is equipped with a PLC + touch screen control system,实时 regulating foaming agent flow (accuracy ±0.1g/s), raw material temperature (±1°C), sponge density stabilized at 40±2kg/m³ (customer requirement 35-45kg/m³);

Online laser thickness gauge linked to the die head, mattress core thickness deviation ≤ ±1mm (traditional ±3mm), meeting \"zoned support\" design requirements (e.g., soft head, firm waist).

2. Continuous production, improving efficiency:

Continuous production line replaced batch equipment, foaming cycle reduced from 45 minutes to 8 minutes, daily core output reached 180 pieces (125% increase);

Automatic Horizontal Foaming Machine 10m long mold design, single成型 length 10 meters, after cutting directly yields 20 standard mattress cores (1.8m×2m), reducing intermediate handling links.

3. Intelligence + Energy saving, reducing comprehensive costs:

Integrated waste heat recovery system, heat generated during foaming used to preheat raw materials, energy consumption per ton of product reduced by 35% (from 1200 kWh/ton to 780 kWh/ton);

Automated production line requires only 3 people per shift (originally 10 people), annual labor cost savings of 900,000 RMB;

No waste edge trim (traditional cutting loss 8%), raw material utilization rate increased to 98%.

Results Achieved

Quality upgrade: Mattress core density qualification rate increased from 88% to 99%, softness/hardness consistency obtained SGS certification, customer complaint rate dropped to 1%;

Doubled capacity: Daily core output 180 pieces, supporting daily mattress production capacity of 150 pieces (originally 80 pieces), peak season order delivery cycle shortened from 15 days to 7 days;

Cost optimization: Annual savings on electricity bills 1.95 million RMB, labor costs 900,000 RMB, comprehensive production cost reduced by 28%, profit margin increased by 15%;

Industry recognition: Became core core material supplier for brands like Sleemon, De Rucci, overseas orders (Southeast Asia, Middle East) proportion increased to 35%.