Bonnell Spring Machines

GENMAX manufactures Bonnell spring machines for mattress plants producing knotted-coil spring units. The two core stations are coil forming and automatic assembly: the coiler draws and knots wire into finished Bonnell coils at set height and turn count, and the assembler laces those coils into a complete spring unit with helical wire.

Bonnell vs. Pocket Spring: Which Line Do You Need?

Bonnell remains the volume construction across much of Asia, the Middle East, Africa and Latin America. The coils are interconnected, so the unit is rigid, cheap to produce, and tolerant of rough handling — and the equipment costs considerably less than a pocket spring line. Wire consumption per unit is higher, but wire is the cheaper input.

Pocket spring units wrap each coil in fabric, which allows independent movement and commands a higher retail price, but needs different machinery entirely. Plants entering the mid-market usually start with Bonnell and add pocket spring capability later rather than replacing it.

Our Bonnell Spring Machine Range

Bonnell Spring Coiling Machine

Forms and knots coils from spring steel wire at set height, diameter and turn count. Wire gauge and coil geometry are changeover settings, so one machine covers the firmness range across your product line.

Bonnell Spring Assembling Machine

Laces formed coils into complete spring units with helical wire, automatically indexing row by row. Unit dimensions are programmable, so single through king runs on the same machine without tooling changes.

For a complete configuration including heat setting, border rod forming and transfer conveyors, see our Bonnell spring production line.

Frequently Asked Questions

What output can a Bonnell line produce?

Output depends on coil count per unit and configuration. Tell us your target spring units per day and mattress size mix, and we will return a line configuration with cycle times and a capacity calculation.

What wire specification is required?

Standard mattress spring steel wire; gauge is selected against your target firmness and coil geometry. We confirm the specification and can recommend suppliers in your region.

Is heat setting necessary?

Heat setting relieves stress in the formed coil and prevents height loss in service. It is standard on units intended for export or for warranty-backed retail, and we include it in line proposals unless you specify otherwise.

Can the assembler handle different mattress sizes?

Yes. Unit dimensions are programmable; changeover between sizes is a settings change, not a tooling change.