5,000 units per shift: Down Inc. is 1st in U.S. with advanced shell tech

Grand Rapids, Mich. – Premium bedding products manufacturer Down Inc. has installed a unique automated pillow shell production system at its newly renovated facility.

Developed by Sweden-based ACG Kinna Automatic, the advanced manufacturing system is currently the only one of its kind operating in the United States, according to Down Inc. The technology automatically measures, cuts, sews, and trims pillow shells according to programmed product specifications, bringing a new level of precision and efficiency to decorative pillow insert production.

Operated by just two team members, the system can produce up to 5,000 pillow shells during a single 10-hour shift at the company’s facility on Evergreen Street in Grand Rapids.

The installation also includes a state-of-the art roll cutting system that ensures consistent fabric preparation before production begins.

See also

• Down Inc. boosts organic luxury with updated bedding collection
• Down Inc. highlights luxury private label capabilities at new showroom

“This investment allows us to further strengthen our manufacturing capabilities while maintaining the quality standards our customers expect,” said David Sweet, President of Down Inc. “We’re proud to partner with ACG Kinna Automatic to bring this innovative technology to the United States.”

Following production, pillow shells are transported to Down Inc.’s nearby plant in Walker, Mich., where they transition into finished pillows through advanced filling, finishing, and packaging processes. The company’s automated filling systems can fill a pillow in as little as seven seconds while maintaining precise product specifications.

The project represents a significant investment in domestic manufacturing, the company said, and positions Down Inc. to continue supporting hospitality, retail, interior design, and private label customers throughout North America.