Many mattress companies are wasting their resources in this small details of bonnell spring production.
Which detail in bonnell spring production is important?
There some details in spring machines which are making an immensive impact on saving raw material (wire) in mattress production facilities. The efficiency in bonnell spring production is not only based on the number of produced springs units per day.
Today sustainability is the most popular slogan for marketing campaigns for mattresses. It is really important to protect our ecosystem and save natural resources for future generations. But when it is comes to taking action about small details to prevent waste many responsible manager or machine operator are closing their eyes.
Today we will explain how you can save approx. 350.000€ by making a small adjustment on bonnell spring machines.
The problem: The tail of bonnell springs
Many companies are still thinking that the extended length of the knot tail is giving an extra strength to the bonnell springs, which is not true.
Based on our experience on spring machines for more than 55 years the ideal knot length is around 2.5 turns without having an extra long end. In many companies they are using a tail, which is 1/2cm too long. The significant point is that the knots are not getting opened easily. It can be also tested by trying to open the knot by hand.
The solution: Adjusments on the machine
For having a real strong knot on the springs, the machine needs to be perfectly adjusted to the ideal wire length for each spring. Additionaly the right positioning of the knotting wheel is very important to have a rounded spring head.
So by extending the length of wire on the knots it not possible to get springs with a better quality, it is quite the opposite because in long term the knot tail can bend and damage the felt and foam layers of the mattress.
Let’s do some maths!
We can use the following formula to analyse the waste on bonnell springs:
Main calculation:
0.59gm waste (2cm on upper knot) + 0.59gm waste (2cm on lower knot) x 30.000 springs (average production of a bonnell spring machine) x 3 shifts x 24 working days x 12 months x 10 years x 1100€/ton.
Details:
1.18gm (each spring) x 30.000 springs x 3 shifts = 106.200gm = 106.20kg waste per day
106.20kg x 24 days x 12 months x 10 years = 305.586kg waste in 10 years
305.86 tons x 1100€ = 336.446€ waste in 10 years
We can also add that we are wasting raw material which will be suitable for production of 50.000 bonnell springs units (single size mattress 140x200cm).
If we multiply this waste to all mattress companies all over the world, we will get a alarming number.
What other details needs to observed in bonnell spring production?
The quality of the wire is extraordinary important for a having a stable production on bonnell spring machines. If the wire quality is not suitable for spring machines, the length of the knot tail will continously change during operation of the machine.
So again and again it needs to be adjusted to get the right spring shape.
There are many other technical details which needs to be considered before buying a machine for spring production.
Our team is here to support you about the choice of spring machines.
Our message is: Sustainability in every step of manufacturing process of furniture
Let us prioritize the efficiency in the furniture production processes, let us go deep into the details to save resources. A little effort make a big difference in long term.
continue reading
