CUTMaster 240 AIR + RollMaster SE

This project was custom-built for a manufacturer specialising in quilts, pillows, and mattresses.

Request

The client needed to speed up their process of cutting pillow covers and wadding layers to precise dimensions. Cotton wadding arrived in bulky rolls that first required spreading across the table in multiple layers. Once spread, these layers needed to be formatted to exact sizes, such as 50×50 cm squares or other.

Challenge

The key challenge was achieving efficient production – they wanted to produce 20 formatted pieces using just two perpendicular cuts rather than cutting each piece individually.

Solution

We designed a 14-meter production line that integrated our CUTMaster AIR spreading machine with a RollMaster format cutting table.

The spreading machine handles the initial layering of the bulky wadding rolls, whilst the cutting table formats the spread layers to the required dimensions with two cuts made at 90° angles to each other.

The production line starts at the front section, where wadding rolls up to 80 cm in diameter are loaded onto the spreading machine. The operator then unwinds the roll layer by layer, building up a stack of 20 layers across the table. The spreading length is limited to where the RollMaster cutter is built into the table surface.

Once all layers have been spread, the stack must be moved to the RollMaster cutting station for formatting. The integrated air blowing system makes this transfer quick — the air cushion allows the operator to slide it smoothly along the table without any risk of the layers separating or shifting out of alignment.

Final Result

The goal was achieved. Watch the video of multiple quilt layers being cut at once: