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Why rollable adhesives provide a more efficient mattress production process

Would you like to increase the efficiency of your mattress production process? Create a safe working environment for operators? Attain the highest ROI in the shortest period of production time? If so, a roll coating system can help you achieve this. 

The installation of a roll coating system as part of the mattress production process yields various benefits. Its successful implementation depends on multiple factors, including the equipment, correct machine settings and the adhesive used. SABA offers exceptional adhesives which enable a mattress production process, using a roll coating system to run as efficiently as possible.

Tonny Zaarbelink
Author Tonny Zaarbelink Head of Product and Application Management

How does a roll coating system work?

Roll coating systems are primarily used for production of all-foam layered mattresses. The flat surface of the foam sheets in layered mattress construction are perfectly suited for use with a roll coater. Adhesive can be applied evenly over the entire area of the foam sheet for full adhesion and strong bonding.

The process is as follows: 

•    Foam sheets are supplied by a conveyor belt, and can be introduced manually, as well as automatically. 
•    Next, the foam sheet proceeds to move below the adhesive applicator roller. The roller ensures the adhesive is applied in a controlled, uniform, precise and consistent manner. 
•    A coating of adhesive is applied to the foam. The foam layers are then assembled. Assembly can be done automatically or manually by operators. 
•    Finally, the assembled foam sheets move into a press, where the bonding process is completed. 
•    The mattress is complete once the cover is attached around the foam layers and is then ready for packaging.

The roll coating process can differ from one situation to the next due to the variety of brands, models and qualities used. Price range and technical specifications also are a factor.

Rollable adhesive activation methods

Adhesives applied with a roll coating system can be activated in two different ways, i.e. by: 

  • Pressure
  • Thermal heat

Pressure

Slight pressure is already applied to the adhesive during the application coating process, which creates initial tack. Once the foam sheets are assembled, they enter the press. The foam sheets are compressed in the press to fully activate the adhesive. The pressure exerted by the press ensures the effective transfer of the still wet adhesive to the other surface to be bonded. As a result, excellent final strength is achieved securing the bond of the foam sheets.

C3 Semi-Automated Lamination Machine
C3 Semi-Automated Lamination Machine
Aper Gluing and drying line
Aper Gluing and drying line

Thermal heat

Certain adhesives can also be activated through heat. The heat causes some of the water in the adhesive to evaporate, which gives the adhesive its initial tack.

This works as follows:

•    The special adhesive is applied to individual foam sheets via a roll coater.
•    Each foam sheet with applied adhesive next passes through an IR or hot air heating tunnel to evaporate some of the water from the adhesive.
•    The adhesive is activated within a few seconds, thus creating initial tack. 
•    After the foams exit the drying tunnel, the layers are assembled to construct the mattress.
•    The assembled foam layers next move into the press. The press transfers adhesive to the surfaces and creates the bond to hold the layers together.

Due to the very short drying time, subsequent production and packaging steps can be carried out immediately.

Our Produce & Pack concept accelerates the drying process and makes it possible to immediately pack and ship the mattress. The key factor in this process is the adhesive contributes to the perfect recovery of the mattress after it is unpacked.

More info about Produce & Pack

Benefits of roll coating versus spray gun

The use of a roll coating system offers a number of advantages in comparison to the use of a spray gun:

Economic benefits

When adhesives are applied with a spray gun, it can be difficult to determine exactly how much adhesive is being used. By contrast, the quantity of adhesive applied with a roller is always consistent. 

By precisely adjusting the rolling machine, the quantity of adhesive applied can be kept at a minimum. The ability to control of the quantity of adhesive applied makes this technique extremely economical. 

Efficiency benefits

Roll coating systems apply minimal quantities of adhesive which significantly shortens the required drying time, making the entire process more efficient than the spraying method. Roll coating processes are generally automated, requiring less time and increasing production speed. 

Safety benefits

A roller system always makes use of water-based adhesives or hotmelts to bond. These adhesives do not display any hazard symbols, as a rule. They are better for the applicator’s health than adhesives which contain VOCs. 

Furthermore, rollers apply the adhesive very precisely without overspray or adhesive particles that end up in the atmosphere. Provided that the applicable safety measures are implemented, this does not need to be a drawback of the spraying method either. 

Opting for a roll coating system

The roll coating equipment may not be a fit for all production situations.  Manufacturing space, personnel along with components/construction of a company’s mattresses can influence the possible integration of a roll coater. Roll coating equipment can be a significant investment. It provides increased speed and efficiency of production, if implemented correctly.

In short, the roll coating system must fit into your production process. We are happy to help you explore the possible options. Do not hesitate to contact us without obligation. We look forward to provide you with custom advice concerning the right adhesive for your application.

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