We know by now compression packaging allows you to ship beds directly to consumers with more efficiency and lower cost. But is the impact compression has on a mattress safe for the bed? Will it damage the product? How can we be sure that it won’t? Is a heavier press better or worse for the product?
In this edition of our STANDOUTS series, we’re going to show you how the features of the press on C3 machines ensure you’ll end up with a beautiful package that’s never over-compressed. Watch to see it in action!
When our engineers talk about the press, one word always comes up: smart. By “smart,” we mean the press is not simply responding to a one-way signal to compress the product. It is constantly receiving feedback and analyzing what is happening during compression. This is largely thanks to our use of hydraulics in the press, which has four major advantages. This press is:
- Fast; the CF1396 can roll package 2+ packages per minute
- Reactive; it receives tonnage feedback from the product and adjusts as needed in real time
- Balanced; all four corners are monitored separately for even force distribution
- Strong; it can handle compressing even the heaviest, most resilient beds safely
The “smartness” of the press and the features it delivers means you’ll get the ideal compression for each product you package.
Use Feedback to Prevent Compression Set
A common concern when discussing compression packaging is compression set, or the product not recovering to its original dimensions due to damage to the foam’s cell structure from over-compression. To help solve this, we’ve done extensive research on density limitations for mattresses, which allowed us to develop our compression calculator. We use this calculator to determine safe compression packaging options for your product, long before you ever have to try it for yourself. (You can read more about this on pages 2 and 3 in our brochure.)
Our press prevents compression set by operating to the recipe designated for the product in production. As the product is compressed, the press monitors its progress and stops compression at the set-point. For example, on our CF1396 with a fixed diameter roll cage, the machine monitors for height and tonnage feedback. Once it reaches one of those settings, the press stops.
If, for some reason, a mattress with different dimensions were to enter the press, the machine would alarm out before compression even began. On the other hand, if a bed of correct dimensions entered the press but had a different foam density, the press may reach its tonnage limits before the proper compressed height could be achieved. The machine will also alarm out in this instance, preventing the mattress from entering the roll cage where it could have otherwise damaged both the mattress and the machine.
With our variable roll cage option, the machine collects additional product data before and during compression. The press can measure for height, tonnage, volume, and density, then communicates those values to the variable cage. This cage automatically adjusts its settings to match, meaning you’ll never be forcing a product to squeeze into dimensions it can’t handle. Sounds like a smart press, doesn’t it?
Protect the Product and Machine With the Four-Corner Controlled Press
We’ve talked about four-corner control before in our brochure and How to Use Data to Improve Manufacturing; hydraulics control the press independently at all four corners to ensure consistent pressure across the product. So, how does four-corner control impact the feedback the press is receiving? What exactly does that mean, and why does it matter?
This is another example of the intelligence built in to our compression machines. The press self-corrects to make sure its distributing pressure in a way that keeps the product symmetric by gathering feedback from all four corners. Without this smart feature, there’s no way of knowing whether a mattress has been compressed correctly and evenly until it’s out of the package. Four-corner control allows the machine to monitor itself end to end and compress each product to the perfect density, every time.
So let’s look back to our initial concerns. Is compression bad for a mattress? Not if you’re using a machine that monitors its measurements in real time. Will it damage a product? Not if you’re using the right amount of tonnage, no more and no less. Is a heavier press better or worse? It depends. Our press has the capacity for more tonnage, but we believe the conversation should start with doing what’s right for each product.
C3’s compression machines all come standard with our smart press technology. Our engineers work with manufacturers to determine the best settings to deliver the best, protected package for your products. Contact C3 today to see what options we have for compression packaging your products.