Customised Non Woven Bed Cover Production With Indian Collaborators
An Indian manufacturing partner producing disposable bed covers for healthcare and hospitality customers, working with our team on a customised bed cover making configuration.
Project Challenge
The finished cover required a quilt cover style banded edge and a folded size that had to stay accurate across a full jumbo roll, on a machine that could also convert between folding methods as their customer mix changed.
Customer Pain Points
- Sewn covers required operators and added needle inspection to a hygiene product
- Folded dimensions drifted as roll diameter decreased
- Changing folding method between products took too long
- Cutting quality fell away as blades wore
Our Solution
The AQ-B(2400) bed cover making machine was configured with 14 sets of high-power screen-following ultrasonic moulds, one set of servo-controlled edge punching moulds for the quilt cover edge banding, and our multi-function special-shaped folder so the folding method could be converted easily.
Production Sequence On The Delivered Line
Jumbo roll unwinding with magnetic powder tension control
Ultrasonic forming through 14 screen-following mould sets
Servo-controlled edge punching for the banded edge
Servo imported cutter trimming
Longitudinal folding on the special-shaped folder
Up to three lateral folds on the servo slider-type fork knife
Supply Chain Coordination
The machine was built at our Dexing factory and exported directly through our Jiaxing office, with the electrical cabinet configured for the customer's supply before crating.
Quality Control
Ultrasonic weld strength and folded dimensions were verified during factory run-off, and six servos under PLC control with a microcomputer display were synchronised at production speed before shipment.
Final Result
The line produces ultrasonic bonded bed covers with a quilt cover style banded edge and a repeatable folded size, with folding methods converted on the machine rather than through mechanical rework.
Customer Benefit
Sewing operators were removed from the bed cover line, folded size became repeatable across a full roll, and the same machine now serves several cover formats.
Machine And Output
Machines Used In This Project
Non Woven Bed Cover Making Machine
Six Servo PLC Control For Ultrasonic Bonded Bed Covers
Model AQ-B(2400)
Medical Bed Cover Folding Machine
Ultrasonic Bonding And Three-Way Folding For Disposable Medical Bed Covers
Model AQ-B(2400)
Non Woven Bed Sheet Making Machine
Disposable Bed Sheet Production With Folding Cutting And Counted Stacking
Model AQ-GF(1200)Case Study Questions
Can you build the same configuration for us?
Yes. The machine in this project was customised from a standard AQ-B platform. Send your cover size, edge style and folding requirement and we quote the equivalent build.
Do you name your customers?
Only with their permission. Where a customer prefers confidentiality we describe the project by market and application instead.
How was the machine tested before shipment?
Ultrasonic weld strength and folded dimensions were verified at factory run-off, and the six servos were synchronised at production speed.
Have A Similar Product To Produce
Describe your cover, sheet or bag and we will tell you which platform it runs on and what it costs.