Dorel system will double futon mattress production
Michael J. Knell -- Furniture Today, August 2, 2004
Montreal — Dorel Inds. has installed technology that will double production of futon mattress pads to 1.4 million units annually at its Dorel Home Products plant here.
The new Airlaid system, developed at a cost of $4 million in conjunction with French equipment maker Laroche, uses natural, recyclable cotton fibers. The custom-designed system is vertically integrated and environmentally friendly, said Chief Operating Officer Pierre Dupuis.
The system replaces a more costly, labor-intensive process that produced futon mattress pads with both cotton fibers and polyurethane foam in a "sandwich style" combining separate layers of materials. With Airlaid, the pads are thermo-bonded and made as a single piece up to eight-inches thick in a continuous manufacturing process.
"The new machinery will help us become even more competitive in the global economy," Dupuis said. "It also permits us to meet the highest environmental standards ... (and) the new standard for open-flame testing that takes effect (in California) next year."
Pads made with the Airlaid system are being shipped to retailers across North America. The old process still is used to make a few specialty mattresses.
Dorel will expand its futon assortment over the next months, although officials said it's too early to say how many SKUs would be added, and how the new technology will affect retail price points.
