We were thrilled to be able to bring the CF1396 Compression Folding System with us to Interzum. Enhanced by the new features developed since its Interzum debut in 2017, the CF1396 creates an ideal mattress package for many different shipping, e-commerce, and retail needs, while keeping the process ergonomically friendly from start to finish. The machine compresses, folds, and rolls a mattress into a cylindrical shape, plus includes an option for easy final packaging.
Whether you’re a foam pourer looking for ways to ship more foam to converters, or you’re a mattress manufacturer looking to deliver more mattresses to consumers through retail and online sales, compression packaging is easily the best way to expand your reach quickly and affordably.
Watch the video to see the process from start to finish:
Bed in a Box… and Beyond
For a mattress manufacturer, one major advantage to using a compression machine like the CF1396 is that it opens your business up to direct-to-consumer sales. Rather than simply auto-bagging mattresses for back room inventory, your end-customer can now get a neatly rolled, wrapped, and boxed mattress right to their doorstep. The CF1396 positively impacts retail store business, too, by allowing you to fit more mattresses on a truck, thus reducing shipping costs.
Compression packaging accomplishes more than fitting more product on a truck. The automation and features of the CF1396 allow you to package various mattresses with the same roll cage and film, while relieving the strain on operators. There are many advantages to using our CF1396 for compression packaging; we’ll briefly walk you through each of these features and how each of them can positively impact your operations.
Boxline: An Ergonomic Way to Finish Packaging
The Boxline addition is the most common add-on for the CF1396. It’s an operator-friendly solution for the final packaging step of boxing the product. The Boxline lifts the final rolled package to waist height and conveys it to a table where an operator can assist it into a box. Without the Boxline, the product falls to the floor and rolls to a stop, where it would then need to be lifted by hand to finish packaging. Instead, the Boxline brings the product to a safe height and helps the operator quickly box and stack finished product.
Traversing Stretch Wrap: Use the Same Film Size for Every Bed
This feature is exclusive to C3 – there’s nothing else like it in the market! Traversing Stretch Wrap allows you to run multiple product widths without having to change out the film. The Traversing Stretch Wrap moves side to side to wrap the product as it is packaged in the roll cage. This saves time and reduces the amount of SKUs of film you need to keep on hand.
CF9500-VC: Compression Folding System with Variable Roll Cage
The CF9500-VC replaces the standard roll cage of the CF1396 with a variable roll cage. This variable roll cage will adjust 6 in (152.4 mm) to create a wider range of package sizes (instead of standard 2.4 in, or 61 mm). The roll cage diameter measures from 9.5 in (241 mm) to 17 in (432 mm). This variability gives you more packaging options within the same machine footprint. This roll cage is an ideal addition for your operation if you package many different SKUs with recipes that require different packaging for each.
SC1536: Second Roll Cage Addition – An Even Smaller Package
The SC1536 takes the compression of the CF1396 one step further. Using similar technology as seen with our TC9513, the product is compressed and rolled to a larger diameter. Then, it passes through the SC1536 where it rolls a second time into a tight, small package that is nearly 50% smaller than standard. We base this figure on a three-layer king mattress packaged to a 23” (584 mm) height and 15” (381 mm) diameter, where standard in the CF is 44” x 15” x 15” (1118 mm x 381 mm x 381 mm). This final product is packed in a smaller box, 16” x 16” x 24” (406 mm x 406 mm x 610 mm) and is more friendly to retail shelves and for shipments. Because of the compression ratio, this addition is product dependent as well. Not all product can handle a double roll, so you’ll need to work with your C3 rep with the roll cage calculator to determine if this is a fit for your product.
FD1000: Force Deflection QA System
We’ve taken you behind the design of the FD1000, and we’ve written about it extensively in our magazine ENG*NUITY. Now let’s take it another step and focus on how it fits in before packaging with a CF1396. Simply put, the FD1000 Force Deflection QA System prevents faulty product from being packaged and sent to your customers. The machine tests a finished mattress at two set points of compression based on the ILD lab test standards and those of ISO 2439. It also fits seamlessly into a production line when placed before a CF1396. Since the CF1396 packages mattresses at an average rate of one every 30 seconds, this 25-second test won’t bottleneck your line. Common issues detected by the test include poorly poured foam, lot-specific issues, and incorrectly built mattresses. The machine data also helps you identify manufacturing inconsistencies in your operations so that you can produce more consistent product.
To help you envision the impact a CF1396 Compression Folding System could have at your facility, here are some example packages the CF1396 creates. The average packaging rate is 120+ per hour, or 24 – 27 seconds per unit. Of course, all products are different; to find out what packaging options exist for your products, contact us.
If you’re looking to automate the packaging process, reduce shipping costs per unit, or create an ideal package for direct-to-consumer or retail markets, the CF1396 is your best next move.