The Research and Development Department of Ikano Industry is a team that:
Experienced technologists and laboratory research specialists study the physical and mechanical properties of PUR foam, latex and nonwovens and interlining.
We produce 4 families of foams with different densities and hardnesses, which in total gives 31 different types. On average, almost 40 pieces of 30 meters long blocks are produced per day, from which the so-called mattress forms are cut out. The pouring time of one block lasts several minutes. Then, the foam grows to a height of 1300mm, and the temperature inside the block, in the final stage, can reach even 160˚ C.
The next stage is seasoning. In order for the foam blocks to be used in the next production stage, they have to wait in appropriate conditions in our seasoning room for up to 120 hours, depending on the type. In Ikano Industry, we also produce Repoliol, which is a raw material for foam production from reprocessed foam production waste. We are the only factory in Europe with a plant for recycling flexible foam.
We produce over 20 million polyester and polypropylene nonwovens annually, In the Nonwovens Production Area machine operators focus on two production lines: the production of polyester nonwovens and polypropylene nonwovens, i.e. interlining. Polyester nonwoven fabric is fluffy and gives covers additional softness, interlining is compressed and then we sew it on the inside of the cover to protect the nonwoven fabric against mechanical damage.
In some families of mattresses, a high-grade interlining forms the underside of the cover. It is an integral part of pockets, i.e. forms for spring mattresses. Both types of nonwovens are used not only in mattresses production but also in the furniture industry, filters production, gardening, automotive, construction and others.
In addition, in our Recycling Center, we recover some of the fibers for production from textile offcuts which are a by-product of the process of making covers.
The production process in the Sewing Area begins with the combination of components in the quilting process (knitted or woven fabric, nonwoven fabric and interlining). Experienced machine operators operate production lines consisting of modern industrial machines.
In the next stage, qualified seamstresses and machine operators complete and connect the remaining elements and this is how we come up with a ready cover.
The Ikano Industry sewing area is extremely comfortable and modern, equipped with an innovative transport system for semi-finished and finished products.
The mattress assembly department consists of several zones:
The mattress assembly process is fully automated. Modern robots improve ergonomics and work efficiency.
Providing a comfortable sleep for millions of IKEA customers around the world is our top priority, so the department aims is to optimize products and processes. We systematically take steps to reduce costs of poor quality (COPQ), improve productivity, increase the availability of our mattresses in stores, and to share quality knowledge with employees.
Modernization and improvements are necessary to maintain the required level of quality and to continuously increase the efficiency of the production process. The Technical Department at Ikano Industry is responsiblenot only for this area but also for developing process of obtaining energy from renewable sources.
Our technical departments:
ul. Magazynowa 4, 64-610 Rogoźno, Polska
(+48) 67 35 25 400
ul. Władysława Jagiełły 19, 77-430 Krajenka, Polska
(+48) 67 35 25 403
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