Manufacture of Bonnell, light-weight and pocket spring cores for the mattress and upholstered furniture industry, including in-house wire production
AGRO International GmbH & Co. KG
Bad Essen (DE) · Szamotuły (PL) · Halberstadt (DE) · Barranquilla (CO) · Spain (Subiñas Springs) · USA (A&S Innersprings)New on Amplifa
About AGRO International
AGRO International GmbH & Co. KG is a third-generation family company based in Bad Essen near Osnabrück in Lower Saxony, and has been developing and producing spring cores for the mattress and upholstered furniture industry since 1948. The portfolio comprises more than 8,000 articles in three product groups: Bonnell spring cores (A.BON), light-weight spring cores (A.LFK) and pocket spring cores (A.POC), including special variants such as DualActive, Interactive, Ergolastic, Squareflaex, Jumboflex SB and glue-free constructions. Production takes place in seven production and warehouse halls with around 40,000 m² of floor space and over 100 machines; spring steel wire comes to a large extent from the in-house wire mill AGRO Steel Wire at the same location. With the A.NEXT recycling system, wire, nonwoven and adhesive can be separated and reused as raw materials. The group also includes the sister companies AGRO Tooling Systems (machine spare parts and own machine construction) and AGRO Nonwoven (nonwoven production in Halberstadt). Through production and joint-venture sites in Poland, Spain, the USA and Colombia, AGRO supplies customers in over 50 countries, with an export share of around 80%.
- Site
- Bad Essen
- Processes
- Manufacture of Bonnell spring cores (A.BON), Manufacture of light-weight spring cores (A.LFK), Manufacture of pocket spring cores (A.POC), point-glued, top-layer-glued, welded, Wire production (wire mill), Manufacture of machine spare parts as well as design and development of own machines, Nonwoven production, Recycling of spring cores (separation of wire, nonwoven and adhesive in a recycling machine), Quality testing (durability/roller testing, material suitability)
- Materials
- Spring steel wire, PP spunbond nonwoven, PP needle-punched nonwoven, PES needle-punched nonwoven, PP recycled nonwoven, Cotton, Adhesive
- Certificates
- DIN EN ISO 9001, DIN EN ISO 14001, DIN EN ISO 50001, OEKO-TEX STANDARD 100, Annex 6, product class I, LGA quality certificates, ISO 9001, ISO 14001, ISO 50001, OEKO-TEX STANDARD 100 (product class I)
- Founded
- 1948
- Employees
- 450
- Industries
- Mattress industry, Upholstered furniture industry
- 01
Wire production (AGRO Steel Wire / Herkules Wire)
- 02
Spring forming (Bonnell, LFK)
- 03
Pocket forming and gluing/welding (A.POC)
- 04
Nonwoven production (AGRO Nonwoven)
- 05
Quality testing (durability, roller testing, material suitability)
- 06
Packaging and racking warehouse
- 07
Logistics with own fleet and forwarding partners
- 08
Recycling (A.NEXT: separation of wire, nonwoven, adhesive)
Materials and Processes
Spring steel wire
Base material of all Bonnell, LFK and pocket spring cores, largely from in-house wire production.
PP spunbond nonwoven
Pocket material for A.POC pocket spring cores.
PP needle-punched nonwoven
Pocket material for A.POC pocket spring cores.
PES needle-punched nonwoven
Pocket material for A.POC pocket spring cores.
PP recycled nonwoven
Nonwoven made from recyclate to increase the recyclability of the spring cores.
Cotton
Natural pocket material, e.g. for the cotton pockets of CottonFlex spring cores.
Adhesive
Used for point-glued and top-layer-glued spring core variants; glue-free variants are available.
Sites
Bad Essen
DEMain site: production, warehousing, administration
- Part weight / size
- Spring core heights up to 250 mm (Jumboflex SB)
- Lot size
- Series
- Materials
- Spring steel wire, PP/PES nonwovens, cotton
- Spring core production machines (over 100)
- Wire mill AGRO Steel Wire
- Recycling machine (separation of wire/nonwoven/adhesive)
- Sorting system
- Racking warehouse (approx. 6,000 m², approx. 10,000 pallets)
- Own vehicle fleet
Szamotuły
PLProduction site Herkules sp. z o.o. including wire mill Herkules Wire
- Lot size
- Series
- Materials
- Spring steel wire
- Wire mill Herkules Wire
- Spring core production
Halberstadt
DEAGRO Nonwoven – nonwoven production
- Lot size
- Series
- Materials
- PP, PES
- Nonwoven production plant
Barranquilla
COJoint venture with Bekaert
Spain (Subiñas Springs)
ESJoint venture with Industrias Subiñas
USA (A&S Innersprings USA)
USJoint venture with Industrias Subiñas
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of Bonnell spring cores (A.BON)Forming | – | – | – | – | Wire (steel) |
| Manufacture of light-weight spring cores (A.LFK)Forming | – | – | – | – | fine, hard spring steel wire |
| Manufacture of pocket spring cores (A.POC), point-glued, top-layer-glued, weldedJoining | – | – | – | – | Wire (steel), PP spunbond nonwoven, PP needle-punched nonwoven, PES needle-punched nonwoven, PP recycled nonwoven, Cotton, Adhesive |
| Wire production (wire mill)Forming | – | – | – | – | Wire (steel) |
| Manufacture of machine spare parts as well as design and development of own machinesEngineering | – | – | – | – | – |
| Nonwoven productionPlastics | – | – | – | – | PP, PES |
| Recycling of spring cores (separation of wire, nonwoven and adhesive in a recycling machine)Engineering | – | – | – | – | Wire, Nonwoven, Adhesive |
| Quality testing (durability/roller testing, material suitability)Testing | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Spring core production machines | – | over 100 | – | – | Bad Essen |
| Wire mill | – | – | – | 2004 | Bad Essen |
| Recycling machine (separation of wire/nonwoven/adhesive) | – | – | – | – | Bad Essen |
| Sorting system | – | – | – | 2014 | Bad Essen |
| Racking warehouse | – | – | – | 2001 | Bad Essen |
| Wire mill Herkules Wire | – | – | – | 2016 | Szamotuły (Poland) |
| Nonwoven production plant | – | – | – | 2022 | Halberstadt |
Additional services
Quality
Raw materials are tested before processing; after every changeover the machine is checked and the first spring core of every new production run is tested separately. Durability/roller testing and material suitability within the scope of LGA certificates; the entire production process is traceable via labels with date, time, machine and order number.
| Evidence | Bad Essen |
|---|---|
| ISO 9001 | |
| ISO 14001 | |
| ISO 50001 | |
| OEKO-TEX STANDARD 100 (product class I) | |
| LGA quality certificates |