PILLOW PRODUCTION LINE FOR AN UPHOLSTERY MANUFACTURER IN ITALY
An upholstery manufacturer in Italy, active for over 20 years in the production of sofas and armchairs, faced a common issue in the polyurethane foam industry: the daily accumulation of foam scraps resulting from cutting operations. Disposing of these residues generated additional costs and negative environmental impact, so the company decided to turn these losses into a source of profit. The chosen solution was to install a complete pillow production and packaging line.
WHY THE LINE WAS CHOSEN
The new line offers a balanced combination of flexibility, performance, and ease of operation. With a capacity of 150–300 kg/hour, the system can process soft materials such as shredded foam, polyester fiber, or mixed materials. Being modular, it can be easily adapted to the production requirements and the available space in the factory. Operation is simple and maintenance is minimal.
MAIN COMPONENTS OF THE LINE
- Foam shredder – turns leftover foam into uniform particles of 5–15 mm, without dust generation;
- Fiber opener – prepares siliconized fibers or textile waste;
- Pneumatic mixer – ensures uniform mixing of materials;
- Filling head and weighing table – for precise dosing of material in each pillow;
- Packing, compressing and rolling machine – completes the process and prepares the product for transport.
foam shredder
fiber opener
pneumatic mixer
filling head
weighing table
packing machine
ADVANTAGES OF THE LINE
- Recycling foam residues, reducing disposal costs and environmental impact;
- Creating a new product line, fully integrated into the existing furniture range;
- Increased profitability, by turning waste into finished products with positive margins;
- High operational efficiency, due to the integrated automated system;
- Consistent quality in filling and packing, ensured by weighing and pressure control systems.
IMMEDIATE RESULTS AND BENEFITS
Shortly after installation, the Italian manufacturer managed to reuse all foam residues generated daily. Besides reducing waste management costs, the company launched a new product line – decorative pillows and furniture cushions – intended for internal use and for resale to other manufacturers.