For European industry
About EUR 2.5 less cost per mattress at Slovenian cost levels. That is an advantage lower wages elsewhere cannot answer, and less dependence on imported petrochemical adhesives.
Foam to foam.
No glue.
Fuzora joins layers of PU foam directly to each other with precisely controlled thermal energy. One platform replaces the four-machine adhesive line, and the mattress is ready for the next stage within seconds.
The challenge
Fifty years of glue, and its hidden cost
Polyurethane foam layers have been bonded with adhesive for half a century. Manufacturers see the adhesive invoice, but not everything the bonding process costs them on the line and in the warehouse.
- 300–400 g
- of adhesive in a typical three-layer foam mattress
- 4 machines
- apply, IR activation, press and trim, linked by conveyors over ~15 m
- 24–48 h
- of drying on pallets before the mattress can move on without restrictions
- 2 × 20–30 min
- two operators clean the rollers at the end of every shift, and kilograms of adhesive are discarded
Europe produces about 50 million mattresses a year, and almost 90 % of them contain PU foam. Glued layers cannot be cleanly separated. Of the ~40 million mattresses reaching end of life in the EU each year, about half are landfilled and only 14 % are recycled.
Sources: EUROPUR / CSIL; EUROPUR (2025).
Solution
Joined by heat. Ready in seconds.
Fuzora's patent-pending process joins polyurethane foam layers directly to each other, with no adhesive between them. The product leaves the machine finished and ready for the next stage.
No adhesive
No glue to buy, apply, store or clean up. The mattress core stays a single material.
No drying
The joint is complete when the mattress leaves the platform. No pallets of work in progress waiting 24–48 hours.
Stronger than the foam
In tensile tests the foam tears before the joint does.
In numbers
What changes on the line
- 0 g
- adhesive per mattress
- 30 s
- maximum per joining cycle
- 4 → 1
- machines on the line
- 15 → 5 m
- line length
Figures for the current 1 × 2 m platform.
Applications
Mattresses first. Then every PU foam product.
- Available now
All-foam & roll-packed mattresses
Foam-to-foam layers, the core of today's bed-in-a-box market.
- Foam layers today
Hybrid & pocket-spring mattresses
The foam comfort layers of hybrid mattresses.
- In development
Upholstered furniture
Sofas and seating, with foam-to-textile joining.
- In development
Automotive interiors
Seats and interior trim made from PU foam.
Working with us
From your foam to your line in three steps
Test on your foam
Send us samples of the foams you use today. We join them on our platform and return tested samples, together with a savings estimate for your line.
Pilot
A pilot run under production conditions confirms quality and cycle time on your products before you commit to anything larger.
Purchase or Glue Savings Sharing
Buy the platform, or pay only from the measured adhesive saving. We propose the model that fits your plant.
Sustainability
Without glue, the mattress core is a single material
Adhesive is the physical reason a foam mattress cannot be recycled: the layers cannot be cleanly separated, so the product remains a composite. A core joined without adhesive is made of a single polymer.
Where EU mattresses end up today
- ~40 M
- mattresses reach end of life in the EU every year
- ~50 %
- landfilled
- 14 %
- recycled
That is about 20 million mattresses sent to landfill every year. Source: EUROPUR, 2025.
For the operator on the line
No adhesive vapours and no solvent cleaning of rollers. The platform has gas and VOC sensing, temperature monitoring, automatic shutdown on overheating, and air extraction and filtration.
For the person who sleeps on it
A glue-free core has no adhesive residues and no related emissions in the bedroom. The absence of a material is easier to demonstrate than a reduction in it.
Team
A team that has run the lines it replaces
-
Danijel Hubman
CEO
More than 30 years in engineering and executive management. Four years as managing director of a mattress manufacturer, responsible for the production lines this technology replaces. Board member of Studio Moderna during its expansion into more than 20 markets.
-
Janez Škufca
CTO
More than 30 years in industrial automation and machine building, systems engineer at Renault. Architect of the platform, its control architecture and the parameter recipe system.
-
Branko Blečić
CCO
More than 20 years in polyurethane foam, mattresses and sleep products. Co-founder and managing director of Bedora, formerly CEO of HealthCare Europe.
-
Anton Papež
Inventor & industrial strategy
Named inventor of the patent application. Four decades of industrial leadership: managing director of TCG Unitech LTH-OL and president of the management board of Interenergo. Slovenian Manager of the Year 2005.
-
Franc Fabjan
Head of R&D
Machine design and industrialisation. Worked on the design and validation of the platform prototypes.
-
Prof. Dr. Janez Tušek
Scientific advisor
Professor Emeritus at the University of Ljubljana and a recognised authority on welding and joining with more than 200 publications. Advises on joining physics and validation methods.
- Patent pending
- European patent application filed in October 2026 for the apparatus, the process, the semi-finished product and the mattress. International extension in preparation.
- Scientific advisor
- Prof. Dr. Janez Tušek, Professor Emeritus at the University of Ljubljana, authority on welding and joining.
- Built in Slovenia
- Designed and manufactured in the European Union.
Contact
Let's test it on your foam
Tell us which foams you join and how many mattresses you make. We will prepare a savings estimate for your line and arrange a demonstration.
- info@fuzora.eu
- Address
- Fuzora d.o.o.
Pleš 20
8362 Hinje
Slovenia