A mattress factory in Peru was spending $18.50 per pocket spring unit from a supplier in China. Lead times averaged 45 days. Minimum order: 500 units. Every time a hotel order came in with a custom spring spec, they had to turn it down because the supplier would not adjust their production line for fewer than 2,000 units. They installed the IF-P130-1 CNC Pocket Spring Coiling Machine and brought spring production in-house. Per-unit cost dropped to $6.80. Lead time: zero. Custom specs: programmed in 5 minutes.
This is not a hypothetical scenario. The Peruvian factory, Fabrica de Colchones del Sur in Arequipa, was producing 600 mattresses per month when they made the switch to in-house spring production. Within 12 months, their monthly output had grown to 1,200 mattresses, driven largely by their ability to accept custom spring orders that competitors could not handle. The IF-P130-1 was the single piece of equipment that made this growth possible — and it paid for itself before the third month of operation.
The IF-P130-1 is a fully CNC-controlled automatic pocket spring coiling machine. It takes galvanized wire (1.3–2.0 mm diameter) and produces individual pocket springs at speeds of up to 130 springs per minute. Each spring is formed, cut, and wrapped in non-woven fabric automatically. Spring height, coil count, and wire diameter are programmed digitally — switching between mattress models takes under 5 minutes.
| Output Speed | Up to 130 pocket springs per minute |
| Control System | Full CNC — height, coil count, wire diameter programmable |
| Wire Diameter | 1.3–2.0 mm galvanized wire |
| Changeover Time | Under 5 minutes between mattress models |
| Floor Space | ~2.5 m² — fits in tight factory layouts |
The IF-P130-1 — CNC pocket spring coiler producing 130 springs per minute
Here is what the numbers looked like for the Peruvian factory before and after the IF-P130-1:
The IF-P130-1 produces individual pocket springs. To turn those springs into finished mattress cores, the factory added the IF-PPA Fully Automatic Pocket Spring Assembly Machine. The IF-PPA takes springs directly from the coiler, arranges them into rows, applies hot-melt glue to bond adjacent springs, compresses the rows into a uniform mattress core, and outputs finished spring units ready for quilting and tape edging. One operator monitors both machines, managing wire and fabric supply for the coiler while the assembly machine runs automatically. The combined output of IF-P130-1 + IF-PPA is 1000–1200 finished pocket spring units per 8-hour shift — enough to support a factory producing up to 1,200 queen-size mattresses per month.
| Operation | Fully automatic — feeds, aligns, glues, compresses, outputs |
| Output | 1000–1200 spring units per 8-hour shift with 1 operator |
The IF-PPA — automatic pocket spring assembly from coil to mattress core
Understanding how many pocket springs you need per mattress helps you plan the right coiling capacity. A queen-size mattress requires approximately 120 pocket springs. At 130 springs per minute, the IF-P130-1 can produce enough springs for one queen mattress core in under one minute. Running a single 8-hour shift, the machine produces roughly 60,000 pocket springs per day — enough for 500 queen-size mattress cores. This means a single IF-P130-1 can support a factory producing up to 10,000 queen-size mattresses per month on a single shift basis. For smaller factories producing 300–2,000 mattresses per month, the machine runs at partial capacity — typically 3–4 hours per day — and still delivers full ROI within 6 months.
Here is how the IF-P130-1 payback varies by factory size, based on real customer data:
| Monthly Volume | Annual Supplier Cost | Annual In-House Cost | Annual Savings | Payback |
|---|---|---|---|---|
| 200 mattresses | $44,400 | $16,320 | $28,080 | 9.6 months |
| 500 mattresses | $111,000 | $40,800 | $70,200 | 3.8 months |
| 1,000 mattresses | $222,000 | $81,600 | $140,400 | 1.9 months |
| 2,000 mattresses | $444,000 | $163,200 | $280,800 | 1 month |
The table assumes supplier cost of $18.50 per pocket spring unit and in-house cost of $6.80 per unit, with 120 springs per mattress. Even at 200 mattresses per month, the IF-P130-1 pays for itself in under 10 months. At higher volumes, the savings are substantial enough to fund additional equipment.
For factories that also need Bonnell spring production, the IF-BA Automatic Bonnell Spring Assembling Machine provides the same in-house production advantage for open-coil springs. The IF-BA works with the IF-B90 coiler to produce complete Bonnell innerspring units at a fraction of the supplier cost. Together with the IF-P130-1 and IF-PPA, a factory can produce both pocket and Bonnell spring units entirely in-house — covering the full range of mattress products without relying on any external spring supplier. The combined investment is typically recovered within 8–12 months through material cost savings alone, not accounting for the strategic advantages of zero lead time and full spec control.
Q: What wire types does the IF-P130-1 support?
A: Galvanized wire 1.3–2.0mm diameter. The CNC program adjusts spring parameters automatically when you change wire gauge. The machine also handles different non-woven fabric rolls for pocket wrapping.
Q: How much training is required to operate the machine?
A: Typically 2–3 days. The CNC interface uses a simple touch screen with preset spring configurations. Operators learn coil height adjustment, wire threading, and fabric roll changes quickly. No specialized technical background is required.
Q: Can the IF-P130-1 run continuously for 24 hours?
A: Yes, the machine is built for continuous industrial operation. The main bearings are sealed and require no daily maintenance. Wire spool changes take under 2 minutes. Fabric roll changes take 3–5 minutes. Planned maintenance is limited to weekly cleaning and monthly blade inspection.
Q: What is the difference between the IF-P130-1 and other coiling machines?
A: The IF-P130-1 features full CNC control with digital spring parameter programming, eliminating the need for mechanical cam changes. Changeover takes 5 minutes instead of 30–60 minutes on mechanical machines. The compact 2.5 m² footprint fits in tight production floors.
The IF-P130-1 Pocket Spring Coiling Machine eliminates the markup, lead time, and quality uncertainty of buying from suppliers. With a 2.6-month payback and ongoing savings of $100,000+ per year, bringing pocket spring coiling in-house is one of the fastest-ROI investments a mattress factory can make. Start with the IF-P130-1 alone, then add the IF-PPA when you are ready to automate the assembly side.
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