Quick question: how much are you paying per innerspring unit right now?
If you're buying from a supplier, the answer is probably somewhere between $8 and $14 per unit — depending on wire gauge, spring count, and your volume. And if you're making your own with old equipment, you might think you're saving money. But let's check the numbers.
A factory producing 400 Bonnell mattresses per day spends roughly $1,600/day on wire at current prices. That same factory buys innerspring units at $10 each — that's $4,000/day just for the springs. The difference — $2,400/day — is the markup you're paying someone else to do what you could be doing yourself.
We ran the numbers with a customer in Peru last year. They were making 500 Bonnell mattresses per day and buying pre-assembled innerspring units from a local supplier at $9.50 each.
| Cost Item | Buying from Supplier | Making In-House (IF-B90 + IF-BA) |
|---|---|---|
| Cost per unit | $9.50 | $3.80 (wire + energy + labor) |
| Daily cost (500 units) | $4,750 | $1,900 |
| Annual cost (300 days) | $1,425,000 | $570,000 |
| Annual Savings | $855,000 | |
That's not a typo. $855,000 per year. Their IF-B90 coiler and IF-BA assembler paid for themselves in under 4 months. Four months. After that, every innerspring unit they produced was pure savings compared to what they used to pay.
The IF-B90 is where the line starts. It takes wire directly from the coil and produces finished, heat-treated Bonnell springs at 80 pcs/min. In one cycle: coil, knot both ends, heat-treat, and discharge. No separate tempering furnace needed. The computerized control keeps every spring identical — consistent diameter, consistent height, consistent tension. That alone eliminates the #1 quality complaint in Bonnell mattresses: uneven springs that cause a lumpy sleeping surface.
Once the IF-B90 produces the springs, the IF-BA takes over — automatically stringing the individual hourglass springs into rows and assembling those rows into a complete innerspring unit. The combination of high working efficiency, simple operation, and stable performance makes it the perfect partner for the IF-B90.
If you're building a new factory or expanding significantly, the IF-BPL100 integrates coiling and assembly into a single production line. Wire goes in one end, finished innerspring units come out the other — with built-in quality inspection and performance testing at every stage. No material handling between steps, no work-in-progress inventory, no coordination between separate machines.
"We used to buy from a spring supplier in the next city. Delivery was unreliable — we kept 3 weeks of inventory just to be safe. That's $120,000 in wire tied up in storage. Now we make what we need, when we need it. Our inventory dropped to 2 days. The IF-B90 and IF-BA paid for themselves in 5 months. And our quality is actually better now — we control the wire source and the spring dimensions."
— Factory owner, Ecuador
"We were skeptical about the 80 springs/min claim. We set up a stopwatch on installation day. The IF-B90 hit 78 in the first minute and stabilized at 81 by minute three. It's been running 16 hours a day for 14 months. One unplanned maintenance — a tensioner replacement that took 45 minutes."
— Production manager, Mattress factory, Morocco
The IF-B90 + IF-BA combo costs about $48,000 delivered. At $855K/year savings, your payback is under 3 months. Can you think of any other equipment in your factory that pays for itself that fast?
The IF-B90 runs on computerized control. Your operator needs to know how to load wire coils and punch in spring dimensions. That's it. The machine does the rest. Training takes half a day.
Send us a sample of your wire before you buy. We'll test it in our Guangzhou factory and tune the machine settings for your specific wire hardness. No surprises when the machine arrives.
If you're buying Bonnell innerspring units from a supplier, you're paying a markup that your competitor — the one with their own coiling and assembly equipment — is pocketing as profit. The IF-B90 and IF-BA eliminate that markup. The machines pay for themselves in months, not years. And the quality you get from controlling your own spring production is better than anything you can buy on the open market.
The only question left is: how many more months are you going to keep overpaying for springs?
Tell us your daily mattress output and current spring cost — we'll calculate your exact savings and payback period. No commitment, no sales pitch.
