Bonnell springs — also known as open-coil or hourglass springs — are the most widely used spring type in the global mattress industry. Their distinctive hourglass shape, with knotted ends, provides proven durability and support at a cost-effective price point. For manufacturers serving the mid-market and budget segments, Bonnell spring production equipment is essential.
Infinity Foam Machinery offers a complete range of Bonnell spring machines: the IF-B90 High Speed Computerized Bonnell Spring Coiling Machine, the IF-BA Automatic Bonnell Spring Assembling Machine, and the IF-BPL100 Full Production Line.
Despite the rise of pocket spring technology, Bonnell springs still account for approximately 60% of the global innerspring mattress market. The reason is simple: Bonnell springs offer excellent durability, proven performance, and significantly lower production costs compared to pocket springs. A well-made Bonnell mattress can last 8-10 years with proper use.
The Bonnell spring manufacturing process involves three main stages: coiling, heat-treating, and assembly. First, the wire is coiled into an hourglass shape and the ends are knotted. The springs are then heat-treated to set their shape and temper. Finally, the individual springs are assembled into rows and laced together to form a complete innerspring unit. Modern automatic machines combine these steps into a seamless, high-speed production line.
A factory producing 1,000 Bonnell mattresses per day requires approximately 600,000–800,000 individual springs daily. Manual or semi-automated production simply cannot achieve this volume — computerized high-speed machines are essential for commercial-scale manufacturing.
Bonnell hourglass springs have been used in mattresses for over 100 years. Their knotted-end design prevents fabric penetration and ensures long-term reliability.
Bonnell spring production requires less wire per spring than pocket springs, and the simpler assembly process reduces manufacturing costs by 30-40%.
Modern computerized Bonnell coilers produce up to 80 springs per minute. Automated assembly lines transform wire directly into finished innerspring units in a single process.
Bonnell mattresses remain the top choice in Latin America, Africa, the Middle East, and parts of Asia — representing billions of dollars in annual demand.
The IF-B90 is a high-speed computerized Bonnell spring coiling machine that produces finished Bonnell springs at speeds of 80 pcs/min. In a single cycle, the wire is coiled into the hourglass shape, both ends are knotted, the spring is heat-treated, and it is then collected in an outlet channel ready for assembly.
A mattress factory in Egypt with a daily output of 1,200 Bonnell mattresses installed six IF-B90 machines to replace their aging mechanical coilers. The factory achieved a 50% increase in coiling capacity, reduced wire waste by 15% due to the computerized control system, and the automatic heat-treating feature eliminated a separate tempering furnace — saving floor space and energy costs.
The IF-BA is an automatic Bonnell spring assembling machine that performs the string combination of double cone springs — connecting individual springs into rows and then assembling rows into a complete innerspring unit. It offers high working efficiency, simple operation, and stable performance.
The IF-BPL100 is the latest integrated Bonnell spring production line that produces complete innerspring units directly from wire. Unlike separate coiling and assembly machines, the IF-BPL100 combines all manufacturing steps — wire coiling, knotting, heat-treating, and unit assembly — into a single automated production line. This reduces material handling, minimizes labor requirements, and ensures consistent quality from wire to finished innerspring unit.
A mattress manufacturer in Nigeria installed an IF-BPL100 production line to serve the growing West African market. The integrated line reduced their production staff from 18 to 6 operators, increased daily output from 400 to 700 innerspring units, and the built-in quality inspection system reduced customer returns by 75% in the first six months of operation.
| Factor | Bonnell Spring | Pocket Spring |
|---|---|---|
| Production Cost | Lower (30-40% less) | Higher (fabric + assembly) |
| Durability | Excellent (8-10 years) | Excellent (8-12 years) |
| Motion Transfer | Moderate (springs linked) | Low (independent springs) |
| Target Market | Mid-market, budget, hospitality | Premium, luxury |
| Global Market Share | ~60% of innerspring | ~35% of innerspring |
| Production Speed | 80 springs/min per machine | 60-150 springs/min per machine |
Bonnell spring production remains a cornerstone of the global mattress industry. With the right equipment — from the high-speed IF-B90 coiler to the automatic IF-BA assembler and the fully integrated IF-BPL100 production line — your factory can produce quality Bonnell innerspring units efficiently and cost-effectively.
Contact Infinity Foam Machinery today to discuss your Bonnell spring production needs and find the right solution for your factory.
Get a free quote for Bonnell spring machines.
