MATTRESS PRODUCTION,
BUILT AROUND YOUR PROCESS
From a Single Automated Machine to a Complete Production Line,
APER develops flexible solutions for mattress manufacturers.
ONE PROCESS. DIFFERENT LEVELS OF AUTOMATION.
Whether you need to automate a single operation or build a complete mattress production line, APER can combine individual machines into a solution designed around your process, production volumes and goals.
START WITH ONE MACHINE. AUTOMATE AS YOU GROW.
SINGLE MACHINE
For a specific production step.
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PARTIAL AUTOMATION
Connect selected processes and reduce manual handling.
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FULL PRODUCTION LINE
Automate the complete workflow from loading to palletizing.
Automation doesn’t have to start with a complete line.
Start where automation creates the most value — and build from there.
Start simple.
A stand-alone hot melt gluing machine. Automate the most critical step, add the rest later.
Build in line.
Gluing, assembly belt and press working together, producing spring mattresses in line.
Go fully automated.
Robot loading, gluing, assembly, cutting and palletising, with minimal manual handling.
GLUING: The APER AX-H automate glue delivery when producing spring mattresses.
- Fully automatic: the nozzles’ glue paths can be set as a recipe or taken automatically from the dimensions of the product.
- Flexible for any production lot: one machine, different mattress sizes and constructions
- Multiple glue patterns: a bar with a minimum of 5 nozzles delivers multiline, spiral or single-line glue, on the perimeter and in the centre.
Numeric control with a stick-proof conveyor. - Glue feeding system chosen for you: melter, pressing plate, gear pump or piston pump, depending on your adhesive and output.
AX-H+ adds automatic recognition of the product and adapts the position and height of the nozzles, each with separate motorisation.
The press that completes the bond
The AX-PRL is designed to follow the gluing operation, so the bond is set under controlled pressure before the mattress moves on. Pressing is fully adjustable: you set the pressing time and the number of pressings per cycle, so the same press adapts to different products and different production requirements.
- Built for demanding materials: effective on any type of polyurethane and on difficult materials such as high-density viscoelastic, mattresses with wide surfaces and multi-layer constructions.
- Rigid and stable: the mechanical structure is made of semi-processed steel plate, which ensures stability and resistance to the stress of repeated cycles.
- Flat where it counts: the resting surface is a fully reinforced conveyor belt, and a balancing bar keeps the pressing plane perfectly parallel to the belt during the pressing phase.
- Ready for the line: it runs right after an AX-H or AX-H+ gluing machine, and can be combined with APER conveyors and roller tables (NT, NTD, NTS, RF) so the product moves smoothly from one station to the next.
Keep the line running, without the manual handling
The AX-ROBOT is an anthropomorphic 4-axis robot that combines electronics, mechanics and APER’s own solutions in one flexible product. Unlike a Cartesian or gantry robot, it is not rigid: with the APER gripper it picks up, handles and positions the product with the correct orientation.
One robot, two jobs. At the start of the line it depalletises: it takes stacked foam sheets from the pallet and feeds the APER gluing machines. At the end of the line it palletises: it aligns sheets one on top of the other, or stacks finished mattresses, in fully automatic mode.
- Grippers made around your materials: pocket or bonnel springs, polyurethane, viscoelastic, felt and more, even different materials on the same line. The gripping system is always developed and customised by APER technicians for your specific requirements.
- Continuous production: 2 to 6 storage positions, depending on the dimensions of the products, so the production cycle never has to be interrupted. Can be combined with the PFS automatic pallet feeding system.
- Less manpower, constant cycle times: the robot takes over repetitive handling and keeps a steady rhythm.
- Reliable and safe: safety systems are installed as part of the solution.