Project: BG-RRP-3.008-0593-C01 “Support for the Transition to a Circular Economy”

In the dynamic mattress manufacturing sector, the optimization of production processes is key to reducing waste and improving environmental efficiency. RED SPRINGS Ltd. is planning significant steps in this direction by implementing new production lines for mattress spring units, including various types of springs.

The new lines will enable automation of production processes, eliminating manual work and the related issues such as material waste. The precise cutting of wire required for spring coiling will ensure the exact amount of material is used, without the need for subsequent trimming. This innovation will reduce raw material consumption by approximately 2–3% per product unit, saving significant amounts of wire, adhesives, and nonwoven fabric.

One of the main benefits of the new technology is the substantial reduction of production waste. Currently, the waste from the production process amounts to around 3 tons of wire per month. With the implementation of the new lines, the company will be able to minimize waste, preventing the generation of around 3 tons of material annually, which will also save about 6 tons of CO₂.

In addition, the new lines will reduce the use of single-use plastic products by eliminating the need for plastic bags to transport finished springs. Instead, the new systems will automatically feed the finished pocket springs into sleeves, reducing the reliance on plastic packaging by about 200 kg per year.

Reducing waste will not only improve the environmental performance of RED SPRINGS Ltd. but will also contribute to a cleaner environment. The implementation of the new lines is an important step towards sustainable development and innovation in mattress manufacturing.