In a world where efficiency and quality are essential in any production process, automation is presented as a solution that not only improves processes, but also redefines the way in which they are conceived and executed.
At ClevLine, we have always been committed to innovation and technology in order to offer our customers highly flexible solutions that allow them to remain competitive over time. Thanks to these values and after years of study and development, we have provided the market with a totally innovative concept in the mattress industry: A fully automatic production line for quilted panels, covers and borders, which also combines the functionality of a multi-needle and a single/double-needle in the same machine, being able to work with a multitude of framed, centred, tack & jump and continuous designs.
In this publication, we will explore in detail how our automatic production line has come to revolutionise the way you manufacture your mattresses, offering advantages that go far beyond efficiency.
The Conventional Process: A Sequence of Workstations
Let’s first talk about what a conventional production process is like. As you all know, the panel production process starts with the preparation of the rolls of raw material, passing through the different quilting, cutting and hemming stations, ending with the palletisation of the finished panels. Afterwards, these panels are transferred to the assembly section, where they will be used for the top and bottom of the mattress.
But how is this production process usually carried out? It depends on how the production plant is organised and the type of machinery available. Therefore, based on our experience with different customers, you will find below the process faithfully represented by a series of graphics:
The Automatic Revolution: Integration and Efficiency
Having seen a fairly common conventional production process nowadays, with the number of stations and operators that usually make it up, let us introduce you to how we approach this production process with our CLEVLINE automatic line.
As in the previous case, we start from the raw material rolls to the palletising of the finished product, with the great difference of not requiring any intermediate handling of the product and including all the quilting processes in the same workstation, where only one operator is needed to supervise and control the entire line.
CLEVLINE has a modular architecture, composed of three independent modules that work together for a common purpose:
CLEVONE: Vertical quilting module with four independent sewing heads, qualified to work with all types of designs and a wide variety of materials and thicknesses, guaranteeing a quality finish on each panel.
CLEVPANEL: Automatic hemming module to finish the perimeter of the panel, with high precision in the measurement, reducing the number of workstations and facilitating the subsequent closing of the mattress.
CLEVSTACKER: Automatic stacking module for a higher level of autonomy in the process, eliminating repetitive tasks of low value for the operator.
Competitive Advantages:
In addition to improving the production process and the quality of the end product, our automatic line offers a host of unrivalled benefits:
1
Increased Efficiency: With a continuous and uninterrupted work sequence, downtime is minimised, resource utilisation is optimised and, as a result, overall process efficiency is increased.
2
Reduced Costs: By eliminating manual handling of products at different stages of the process, labour and production costs are significantly reduced.
3
Space Optimisation: By integrating all processes into a single workstation, the need for additional space and machinery is reduced, leading to considerable savings in floor space.
4
Improved Product Quality: The automation of processes reduces the risk of damage and flaws during the manufacturing process, ensuring greater consistency in the quality of the final product.
5
Flexibility and Adaptability: Our line allows quick and precise adjustments according to specific production needs, combining the functionality of a multi-needle and single/double-needle in the same machine.
6
Greater Process Control: Automation allows greater control and supervision of the production process, as all parameters and variables can be monitored and adjusted in real time.
7
Operator Care: It frees the operator from repetitive and routine tasks, allowing them to focus on higher value activities such as production process supervision, quality control and problem solving, providing them with greater job satisfaction.
The first 100% digital edition of Interzum will take place from May 4 to 7, 2021, and ClevLine will be present at it!
Due to the current situation, a completely virtual stage has been created to hold one of the leading trade fairs in the mattress sector.
From Interzum @ home you will be able to speak directly with our team, arrange a visit to see the complete line in full operation, download our catalogs, and see everything we have prepared for you.
Soon we will provide the link so you can come and be part of this new experience!
Never has been so easy to be at Interzum
In the times we are living, we believe the best way to be near you is open the doors of our company.
ClevLine wishes you all the best, let’s get through this together!
The new quilting machine that, under the ClevLine brand, is designed to respond to the new trends and demands of the Mattress Industry.
The duplication of production, the optimization of manufacturing times, the conscious use of material and its limited occupation in plant are some of the aspects that we have taken into account when developing ClevOne.
Its own technology and a structure composed of functional blocks specifically created and developed for ClevOne, make it the best option to produce quilted material.
Designed to adapt to new trends
The new trends in terms of composition, materials and fabrics make the Mattress Industry, a sector in constant change, which has motivated us to create a quilter capable of making a difference. For its design, we take in count the needs and expectations observed in our customers, and therefore ClevOne works in vertical position, occupying 35% less in plant than conventional quilting machines.
Our DNA values captured into this new identity.
Proven experience in sewing technology
This is possible thanks to our sewing technology available to their heads, in which we have turned all the experience and knowledge acquired during the last decade.
With more than 300 sewing heads manufactured for ClevPanel, our refined know-how and an engineering team recognized as Motion Control Specialist by Siemens, the ClevOne sewing heads are capable of processing materials between 1 and 8 cm thick without any difficulty.
This is due to our development of Quilting Motion System, through which the flow of material is done vertically synchronizing with the transverse movement of the sewing heads, obtaining a quality seam in all areas of the design of the quilted material.
ClevDynamics
But undoubtedly, one of the strongest points of ClevOne is the technology that it integrates.
It has ClevDynamics, a module developed entirely by our specialized programming team, in which the day-to-day needs of the production plants have been contemplated, allowing the connection of different departments with ClevOne, from two different profiles: Operator, focused to the operators and Connect, focused on the production responsible.
Through these two routes, the production queue will become dynamic, feeding as the production manager adds the production orders whose references will automatically regroup facilitating the work of the operators in plant.
