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In response to the growing demand for its bedding machinery in the country and other 130 countries it serves, Bursa-based Elektroteks Co. increased its production facilities from 150,000 square feet in 2019 to 450,000 square feet at the end of this year year.

The first step of this two-year expansion took place in 2020, when Elektroteks completed the construction of a 150,000 square foot facility in Bursa. The new factory is only 10 minutes away from the first factory, doubling the company's production capacity and increasing the number of employees from 160 to 250.

But Elektroteks did not stop there. The company has begun construction of an additional 150,000 square foot facility at its new base and has invested $16 million in processing centers, a coating line, test laboratories, and other upgrade projects. 

"The demand for our machines is growing rapidly," said CEO Serkan Güler. "We are developing new machines very quickly and producing smarter and more integrated systems, which has led manufacturers to choose us."

Bursa, Turkey, where two 150,000 square feet facilities are operated. It is adding a third factory of the same size.

Mattress machinery supplier. The company's production lines include gluing lines, packaging lines, hemming machines, quilting machines, edge machines, rolling cutters, automated smart mattress assembly lines, and various conveyors and stackers.

Founded by Osman Güler in 1991 

Osman Güler and his sons Serkan and Orhan.

Elektroteks was founded in 1991 by Serkan Güler's father, electronic engineer Osman Güler, and initially focused on providing software and control solutions for the textile, automotive, woodworking, food processing and packaging industries. In 2006, the company produced the first double-head continuous quilting machine, and then as the business grew, it began to shift more energy to mechanical production, especially mattress machinery. In 2015, Elektroteks phased out products from other industries, focusing on foam and quilting machinery for bedding production. 

According to Serkan Güler, today, Elektroteks produces almost all the equipment that may be needed in a mattress factory, with the exception of spring unit machinery. The company sells everything from a single machine to a fully integrated system at all stages of mattress production. Its product line includes gluing line (hot melt glue machine and water-based gluing machine), packaging line (wrapping machine, roll wrapping machine and foam machine), hemming machine, quilting machine (multi-needle quilting machine, single-needle quilting machine) Sewing machine and overlocking machine), frame machine (frame quilting machine, handle connector, overlocking machine, frame processing machine and zipper sewing machine), rolling cutting machine, automatic intelligent mattress assembly line (including robot) and various conveying Machine and stacker.

"We are focused on turnkey factory automation," Güler said. "These smart systems include glue spreaders, tape edge banders, robots, bagging machines, reel compressors, stackers, etc., depending on the tailor-made layout created for each customer."

"We can easily say that when we started with the customer, improving every operation of their factory was a very continuous process," he continued. "Usually, this is a marriage. Ninety percent of our income comes from this long-term cooperation."

Güler said that in the future, Elektroteks' main goal will be to help manufacturers create "a factory where everything is self-managed and fully automated." Such facilities will "have fewer or no personnel in most production operations, especially non-value-added operations," such as moving mattresses in factories or packaging finished products. 

In recent years, the rapid growth of the cassette bed industry has created a demand for Elektroteks roller compressors and other cassette bed production lines. "This trend has undoubtedly created new demands for different types of machines, such as laminating, sock filling machines, automatic box making and filling systems, zipper closure machines, etc.," Güler said. "We are able to quickly create solutions for these needs, and customers are willing to cooperate with us to carry out their projects in these areas."

This year, Elektroteks launched a lamination and roll packaging line for boxed bed manufacturers to reduce labor and speed up the assembly of mattress layers, Güler said. This series is suitable for all types of rolled mattresses, from thin mattresses to heavy tri-fold mattresses. The system combines the company's WBX glue production line with its ET-ROLL-400 series of automatic compression, folding and roll packaging machines. 

The latest products of the ET-ROLL-400 series include the ET-ROLL-440, which has a smaller footprint and simpler operation than other machines in this group. ET-ROLL-440 can sense when and whether to fold the mattress according to the size, and can fold up to three folds.

For traditional bed manufacturers, Elektroteks offers a new type of hemming machine, which says "combine flanging and cutting into one automated operation." Güler said that this product called Hemmer has quickly become one of the company's best-selling products of its kind. 

“One of the most time-consuming parts of mattress production is flanging the quilted panels,” Güler said. "Due to its design, Hemmer can not only help you fully automate the flanging process, but it can also avoid wasting any material that was cut in traditional flanging and put into the trash can."

Güler said the company plans to launch a new multi-needle quilting and hemming production line in the third quarter of 2021, "this will bring a very different concept to the quilting department." 

When manufacturing machines, Elektroteks used the talents of its 42 engineers. The group includes 4 quality engineers, 8 software and electronic design engineers, 12 mechanical design engineers and 10 engineers specializing in production and project planning. The team also includes eight engineers focused on after-sales support. 

“In terms of service and R&D, we are very mixed because it is difficult to separate design from prototype production in the machinery industry,” Güler said. "But in general, I can say that 40% of engineers are dedicated to research and development."

When Elektroteks sets out to develop or improve a machine, a priority is to reduce the level of human involvement in running it. “When we manage, we can reduce labor costs and provide more consistent product quality, traceability and autonomy,” Güler said. "Of course, security is not just a discussion, but a must."

As a leading supplier of smart mattress production lines, Elektroteks is also looking for new ways to make its machines work together more effectively. “We provide hundreds of connected production tools for the bedding industry,” Güler said. "Our production line can track the entire production and transportation cycle, from customer orders to mattress transportation. We are very good at mattress assembly and mattress handling management in the factory, as well as the participation of robots on the production line." 

"Of course, in terms of compatibility and the overall success of the project, having all these machines provided by one factory provides the best efficiency," he added. "But we also provide many efficient and unique solutions for roll packaging, quilting and frame production."

Although energy and compressed air consumption are also important factors in the development of new products, "I can't say that they are the most important factors when designing machines," Güler said. "But when we complete the design, we will strive to minimize the consumption of electricity and compressed air without sacrificing performance and durability." 

Güler adds that this approach usually involves reducing energy waste, not reducing operational performance. "In other words, we let our machines consume more energy only when needed. But we use first-class components in terms of energy efficiency, and we never drive our motors without energy-saving inverters to get the most out of the smallest energy. Output."

Güler said that in order to support its customers, Elektroteks has more than 50 employees "traveling around the world for installation and service." "But 95% of service and support is performed remotely through the Elektroteks Connected Service platform."

The company's team of eight dedicated after-sales service engineers focuses on remote customer support, with senior management also participating in the service. “During the pandemic, we expanded our team of online support engineers to improve our resources to guide capable customers in installing their equipment,” Güler said. "However, since most of our installations are large-scale lines or equipment, we have never stopped customer service and installation visits, but the percentage of remote installations has increased a lot for a single machine."

In the United States, Elektroteks operates a parts and service center, which opened in 2018. The center is located in Absecon, New Jersey, enabling U.S. customers to obtain rapid after-sales support. Güler said the site has a five-person team that continues to grow.

To ensure the performance of the new machine, Elektroteks has established a detailed quality management system in its factory, from the acceptance of raw materials to the installation of finished machines in customer facilities. Quality control takes place at every stage of production, and parts are individually inspected and measured before assembly. Before shipping any machine, every key function is tested to ensure normal operation.

With extensive experience in software and controls developed before launching its own machine production line, Elektroteks has "strong problem-solving capabilities and our unique, multidisciplinary approach to design," Güler said. At the same time, he said, "The most important engine that may stimulate our growth is that we are very service-oriented and treat every problem as an'emergency' for the company."

Elektroteks has invested heavily in its service capabilities and does not regard its service or parts functions as a profit center. “In addition, as a family business, we can make decisions faster because our reputation and reputation always come first, not money,” Güler said.

Although Elektroteks has been in business for 30 years, it is a "young company," said Güler, who was appointed CEO in 2020. At only 32 years old, he is the company's fourth largest engineer. Two of the older engineers are his brother Orhan Güler, who served as chief technology officer, and his father continued to serve as president.

“We have a vibrant culture and we are all very proactive,” said Güler, who grew up working in the company and then received a bachelor's degree in mechanical engineering from Bogazici University in Istanbul. He also studied at the University of Wisconsin-Madison. 

When he joined the company in 2006, it had only 60 employees. Of these 60 employees, 40 are still working at Elektroteks, Güler said, “At least 25 people have worked with us for more than 20 years. Although we believe in young blood, we hope to work with them for many years.”

Looking to the future, Güler is excited about the opportunities that the sleep industry has. "I can't say it's easy, but there are many ways to differentiate yourself in our industry," he said. "At least for the next 10 years, we have many new projects underway, and we are investing in the talent we need to realize our dreams when we introduce new equipment to the market."

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