For three years, our Bonnell spring department ran with eight workers per shift. Two operated the IF-B90 coilers, two managed the IF-BA assemblers, and four handled the manual transport, positioning, and stacking of spring units between machines. It was noisy, labor-intensive, and the main source of worker fatigue claims in our factory.
When we discovered the IF-BPL100 Fully Automatic Bonnell Spring Production Line, we realized we had been running our spring department the hard way. This single machine takes steel wire from one end and delivers fully assembled, tied Bonnell spring units at the other—all with one operator monitoring the process.
Our Bonnell spring production before the IF-BPL100 was a multi-step process spread across three separate machines. The IF-B90 Bonnell coilers produced individual springs at high speed. The springs then had to be manually collected, transported to the IF-BA assembling machines, and fed into the assembly line. The assemblers tied the coils together into units, and then workers manually stacked and palletized the finished units.
The coordination between machines was a constant challenge. If the coiler output slowed down, the assemblers had to wait. If the assemblers fell behind, the coilers had to stop. The manual handling between steps created bottlenecks that limited our overall output to approximately 180-200 units per shift.
Labor costs were the biggest issue. Eight workers per shift, two shifts per day, at approximately $2,600 per worker per month meant a monthly labor bill of $41,600 for the spring department. And we still had to deal with quality issues from inconsistent handling between stations.
The IF-B90 High Speed Computerized Bonnell Spring Coiling Machine was a reliable machine individually, but the disconnected workflow meant we never achieved its full potential throughput.
The IF-BPL100 Fully Automatic Bonnell Spring Production Line is a complete turnkey solution that integrates coiling, conveying, assembling, and stacking into one continuous process. Steel wire enters at one end and fully assembled, tied, and stacked Bonnell spring units exit at the other.
The IF-BPL100 occupies roughly the same floor space as our old coiler + assembler combination, approximately 45 square meters. It requires a standard 3-phase electrical connection and compressed air supply. Installation took four days, including calibration and operator training.
The operator training was surprisingly simple. Our lead IF-B90 operator learned the IF-BPL100 control system in two days. The machine runs continuously during the shift, with the operator monitoring the wire supply, checking output quality, and clearing the finished pallets.
The labor cost savings alone were dramatic. Monthly labor for the spring department dropped from $41,600 to $5,200, a saving of $36,400 per month. Combined with the output increase from 200 to 420 units per shift, the per-unit labor cost dropped by 62%.
At an equipment cost of approximately $255,000 and monthly labor savings of $36,400, the IF-BPL100 paid for itself in exactly 7 months. This does not include additional savings from reduced defect rates, lower electricity consumption, and reduced worker compensation insurance premiums.
The quality improvement from the IF-BPL100 was immediate and measurable. Our old multi-machine system introduced variability at every transfer point. Springs could shift during manual transport. Tying tension varied between assemblers. Stacking damage was a constant issue.
The IF-BPL100 eliminates these transfer points entirely. The springs move from coiling to assembly to stacking in a continuous, automated flow. Tying tension is digitally controlled and consistent from the first unit to the last. Stacking is automated, eliminating handling damage.
Our defect rate dropped from approximately 4% to under 1%. This reduction alone saves us approximately $3,800 per month in material waste and rework labor. Our customers have noticed the improvement—spring units from the IF-BPL100 are visibly more uniform in height and alignment.
The CNC control system also allows us to store unit specifications for each customer. When a repeat order comes in, we simply load the saved configuration and the machine sets itself up. This has reduced setup time between orders from 30 minutes to under 5 minutes.
The IF-BPL100 arrived in three shipping crates. Infinity Mattress Machinery's installation team assembled and calibrated the machine in four days. The machine required a 3-phase 380V electrical connection and a compressed air supply at 6-8 bar. We prepared the floor space before arrival, so installation was on schedule.
Operator training was conducted on-site over two days. The lead operator learned the CNC control system quickly because it uses the same logic as the IF-B90 control. The main difference was learning to monitor the continuous flow rather than managing separate machine cycles.
We reassigned the seven displaced workers to other departments. Two went to the pocket spring line, two to the tape edge department, two to quality control, and one to shipping. No one was laid off, and the reassignments actually improved morale because workers moved to less repetitive roles.
After nine months of two-shift operation, the IF-BPL100 has been remarkably reliable. The coiling section has required standard wire guide replacement every three months ($45 per replacement). The tying mechanism needed adjustment at month two (minor tension calibration, handled by operator). The stacking mechanism needed a sensor alignment at month five (15-minute fix).
Total maintenance cost in nine months: approximately $180. Zero unplanned downtime. The machine has run for over 3,500 production hours combined across two shifts.
Daily maintenance takes 15 minutes: cleaning the tying area, checking wire tension, and inspecting the stacking mechanism. Weekly maintenance adds 30 minutes for lubrication and visual inspection of drive belts and bearings. Infinity Mattress Machinery provided a detailed maintenance schedule and video guides for all routine procedures.
Energy consumption is reasonable. The IF-BPL100 uses approximately 22kW during normal operation, which is slightly less than our old coiler + assembler combination (approximately 26kW combined). The reduced energy consumption saves approximately $350 per month in electricity costs.
With the IF-BPL100 handling our Bonnell spring production so efficiently, we had spare capacity on our IF-B90 coiling machines. We decided to diversify into zig-zag spring production for the furniture industry. The IF-Z2-PGY High Speed Sofa Zig-Zag Spring Forming Machine was a natural addition.
The IF-BPL100 handles the mattress spring demand efficiently, freeing up our IF-B90 for sofa and furniture spring production. This two-line approach has increased our total spring output by 35% without adding headcount.
The furniture industry market for zig-zag springs is substantial. Sofa manufacturers, recliner producers, and furniture frame builders all use zig-zag springs. The IF-Z2-PGY produces up to 800 springs per minute, generating an additional revenue stream of approximately $8,000 per month.
Looking back, I wish we had invested in the IF-BPL100 from the beginning. The integrated production line eliminates the complexity, labor, and quality issues of running separate machines. One operator produces more than eight workers did before, with better quality and consistency.
Infinity Mattress Machinery has been manufacturing Bonnell spring production lines for over a decade. Their machines carry CE and ISO 9001 certification. Contact them for a consultation on the IF-BPL100 or the IF-B90 for your factory. They will help you calculate the ROI based on your current production volume and labor costs.
Tell us about your current spring production. We'll calculate your savings with the IF-BPL100.
