Products 02/05/2017

Bäumer’s new nesting program - mattress nest

Fully automated nesting of daily mattress production – promptly planned and true to quantity

Mattress nesting is simplified

When using high-quality materials in a sophisticated and expensive manufacturing process, it is essential to make the best possible use of resources. Nesting programs therefore have been standard for some time now; in cases where, for example, short blocks must first be split horizontally and then, using nesting software, vertically contoured. 

Bäumer has now developed a new software for horizontal contour cutting machines which automatically put different mattress programs together, nesting them in a foam block (short and long blocks).  

Fully automated nesting of daily mattress production – promptly planned and true to quantity 

Up until now, the daily production from importing to finishing had to be planned manually. Manual nesting, however, is not true to quantity because the machine operator nested only one type of mattress from the block until the complete block was full. This inevitably resulted in overproduction and warehousing. 

Bäumer Mattress Nest makes it possible to carry out nesting true to quantity and fully automatically by planning the complete daily production in one go. Less manpower is required for planning and machine operation. Manual intervention in production is not necessary, but still possible. The complete production is quicker and more cost efficient.   

Automatic creation of cutting programs and cutting jobs

Bäumer Mattress Nest imports the order data into the system every day or for several days and first sorts automatically them according to the required qualities. Then programs for different mattresses which can be cut out of a short block or long block are optimally nested automatically, and the cutting programs created in this manner are executed in one continuous process on the BÄUMER horizontal contour cutting machines.

Because the cutting program executes the main program (e. g. the mattress contour) and the side programs (e. g. cutting the mattresses to length) in one continuous process, different mattress types (e. g. children's mattresses and overlengths) can be processed in one single short block.

In addition, the program automatically detects during nesting whether different mattresses have to be processed without any interval between cuts or whether an interval must be maintained. The remaining capacity of a residual block is also identified and factored into the calculations allowing for a freely selectable, tolerable waste quantity. In case of larger residual blocks, the order list can be filled with standard sheet dimensions or other orders.

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