A growing mattress manufacturer based in N'Djamena, Chad, recently faced serious production challenges as demand surged in both domestic and neighboring West African markets. Their manual tape edge process was labor-intensive, error-prone, and inefficient — making it hard to meet order volumes and quality standards.

Challenges Before Automation:

Heavy reliance on skilled operators for manual tape edge sewing.

Time-consuming mattress flipping and corner turning, requiring two to three workers per station.

High defect rate of nearly 30%, especially on thicker mattresses and pillow-top models.

Lost a major $50,000 export order due to quality issues related to uneven edge stitching.

The Zolytech Solution:

After evaluating several suppliers, the company chose Zolytech ZLT-TE5A, thanks to its reputation in emerging markets, remote support capabilities, and advanced automation design.

Key Features That Made the Difference:

✅ Automatic Mattress Flipping and Corner Turning – dramatically reduced the need for manual handling, improving workplace ergonomics.

✅ Intuitive Control System–simplified training and enabled operators with minimal experience to run production lines.

✅ Precision Stitching Technology–delivered uniform, clean tape edging, especially important for premium export models.

Results After Implementation:

✅ Production Output Doubled: Capacity reached 15–20 mattresses per hour, up from 8–10 previously.

✅ Labor Reduction: One operator now manages the process where 2–3 were needed before.

✅ Quality Improvement: Defect rate dropped to under 5%, meeting export standards.

✅ Operator Feedback: Staff reported easier, less physically demanding work and improved morale.

The plant manager noted:

“ZLT-TE5A was a turning point for us. We’ve cut costs, improved quality, and our production team is happier. Zolytech support during installation and training was professional and timely. We’re now considering upgrading additional lines with their equipment.”