Global Systems Group, the machinery division of Leggett & Platt Inc., says its new Gribetz International XT9 Stitch Bridge has drawn a lot of interest from mattress manufacturers since its introduction at Interzum Cologne in May. The machine has the potential for being a game-changer for the industry, the Carthage, Missouri-based company said.
The XT9 will be showcased at ISPA EXPO March 18-20 in New Orleans. The equipment offers bed makers an alternative to the use of adhesives and lamination machinery, GSG said, with its “thread-based lamination,” or TBL (a patent-pending process). Basically, the XT9 stitches together all the mattress comfort layers, bonding them securely without the use of glue.
“When we developed the XT9 we were simply trying to provide our customers with a more cost-effective alternative to a messy process,” said Paul Block, GSG president of sales. “What we’ve learned since then is that this new process is an even bigger story. We knew the machine could cut materials costs dramatically, but customers have been equally excited about the sustainability of the TBL process.”
The list of benefits and potential benefits of switching to TBL keeps growing, Block said. For one, the per-piece cost of assembling beds can drop from several dollars (in adhesive costs) to several pennies (thread cost).
Finished products using TBL have passed every well-known mattress durability test from the Rollator to the roll-packing test.
Block ticked off numerous other benefits of TBL for manufacturers, for consumers and even for mattress recyclers.
For manufacturers, TBL means much faster production times as multiple layers can be sewn together in seconds and finished beds can immediately be packaged and shipped. It’s a more environmentally friendly process to bond with thread, and far less complicated for manufacturers when it comes to complying with regulations related to the use of chemical components (no storage, safety or disposal procedures to follow), Block added.
The TBL process also has resonance with a wide swath of consumers who are concerned about the use of any chemicals in their beds and express concerns about off-gassing in foam mattresses, Block said. In addition, foam beds bonded with thread, not glue, offer improved airflow and are much easier to disassemble and recycle at the end of life.