Since its foundation, Bachmann Schlafsysteme GmbH has established itself as a leading supplier of slatted frames for the mattress, vehicle and caravan industries. With a production area of approx. 12,000 m² and around 150 employees, the company produces up to 1,600 slatted frames every day. Bachmann focuses on the development and manufacture of high-quality sleep systems, especially slatted frames, which are crucial for the comfort and quality of modern mattresses and sleep solutions.

Previously, the company packaged the slatted frames in shrink film with plastic protective edges. However, this method offered only limited protection and no longer met the increasing demands of customers and markets, particularly in terms of sustainability. The shrinking process has a high energy consumption and therefore very high energy costs. Bachmann had been looking for improved packaging for over a decade.

Initial discussions with suppliers of paper-based packaging solutions were held back in 2005. Two key drivers for the implementation were energy savings and 100% elimination of plastic in order to significantly optimize the CO2 footprint.

During further research, Bachmann came across the Kraft Group, whose close cooperation with a corrugated cardboard manufacturer and comprehensive expertise in automation were convincing. The decisive turning point came with the Kraft Group's VPS100 cardboard cutting machine. This machine enables the production of custom-fit and individual corrugated cardboard packaging that is both functional and visually appealing. The small features and details of the VPS100, its intuitive operation and the continuous further development of the technology were particularly convincing.

With the VPS100 carton cutting machine, Bachmann can produce the right packaging, at the right time, in the right quantity. This reduces cardboard consumption to the necessary level, saves on expensive filling materials and recovers valuable storage space. The VPS100 machine optimally prepares the products for transportation by using precisely fitting outer packaging made of continuous corrugated cardboard to avoid expensive transport damage.

The new packaging solution offers numerous advantages:

• Sustainability: 100% elimination of plastic in the packaging
• Energy efficiency: > 50% energy savings compared to shrink tunnels
• Quality: Lower complaint rates
• Product protection: The packaging provides optimum protection for the slatted frames, especially during transportation to the end customer.
• Appearance: The attractive packaging signals quality and leaves a positive impression on the customer.
• Handling: The improved packaging designs make it easier to carry the products, which is a relief for the delivery service.

Another reason for the decision was the extensive range of training and services on offer. The Kraft training courses turned Bachmann's own employees into machine experts, which further strengthened the company's efficiency and independence. One highlight is the integrated “Kraft Box Designer” software, which allows employees to independently and easily create new individual packaging designs or optimize existing ones.

The automation expertise of the Kraft Group for future system expansions also played an important role in the purchase decision.

Numerous customers have already switched to the new packaging made from continuous corrugated board and demand is growing steadily. The proportion of cardboard packaging is currently around 40% and is expected to rise to up to 80% in the coming years. Cardboard packaging is particularly popular in the premium segment.

With the VPS100, Bachmann Schlafsysteme has taken an important step towards modernized packaging processes. The next step could possibly be a partial automation of the packaging process.

By investing in sustainable packaging technology, the company has taken a significant step into the future and is ideally equipped to meet the challenges of the coming years.

www.bachmann-schlafsysteme.de/

Would you like more information? Please contact us!

Jens Kühmann
Packaging
+49 2944 804-354
j.kuehmann@kraft-group.com