Following major investment in advanced manufacturing, innovation, sustainability and people, Kaymed is set to unveil “the next generation of sleep products” at this year’s Bed Show.
Kaymed has completed a landmark £3m transformation programme designed to accelerate innovation, strengthen manufacturing capabilities and deliver greater value for customers and consumers across the UK and Ireland.
At the heart of the programme is the installation of a new Laader Berg Maxfoam continuous PU foam pour line at the company's Dublin foam manufacturing facility. The £2.7m investment introduces advanced automation, real-time monitoring and enhanced production traceability, creating one of the most technologically advanced flexible foam manufacturing environments in the region.
Kaymed says the new equipment delivers improved product consistency, enhanced quality assurance and greater manufacturing efficiency, enabling it to further expand its successful portfolio of Fusion speciality comfort foams. The investment will also reduce waste streams by almost 2% and lower energy consumption by approximately 3.6%, supporting both operational excellence and environmental sustainability.
A further £350,000 investment in C3 Technology foam block compression and roll-packing equipment strengthens Kaymed's sustainability and logistics capabilities. By significantly reducing shipping volumes (up to 8 x better load yields), the technology improves transport efficiency, lowers carbon emissions and enables more sustainable movement of products throughout the supply chain.
Kaymed has also implemented a new Advanced Planning and Scheduling (APS) platform, providing end-to-end visibility across the manufacturing process, from foam production through to finished mattresses. By integrating every component, work centre and production stage across both foam and finished mattress operations, the system enhances planning accuracy, streamlines decision-making and improves responsiveness to customer demand.
For partners, this investment translates into improved service levels, increased supply chain visibility, enhanced product availability and a more agile manufacturing operation capable of responding quickly to changing market needs, says Kaymed.
Ahead of the curve
Beyond investment in equipment, the transformation programme has significantly strengthened Kaymed's ability to develop, test and commercialise innovative sleep solutions. Upgraded factory environments, expanded production capabilities and a new state-of-the-art laboratory provide enhanced facilities for product development, testing and validation.
MD Aiden Costello says: “These investments across our people, technology and manufacturing capabilities strengthen every part of our innovation platform, from foam development and bed-in-box production to premium finished mattresses. Together with the spring expertise of Leggett & Platt, it gives us a unique opportunity to create sleep products that others simply cannot replicate.
“Most importantly, these investments enable us to help our customers win through better innovation, more reliable supply, improved sustainability and enhanced sleep experiences for consumers.”
Kaymed is one of the few fully vertically integrated sleep manufacturers in the UK and Ireland, with the capability to develop and produce every major component of a finished sleep system. From advanced comfort foams and fibres to world-class spring technologies available through the Leggett & Platt group, this level of integration provides customers with greater quality control, product innovation and supply chain resilience, says Kaymed.
Alongside investment in plant, technology and product development, Kaymed has made a significant investment in people, strengthening its leadership, technical and operational capabilities through 14 specialist appointments over the past year. New roles spanning engineering, supply chain, planning, finance, health and safety, laboratory testing, virtual product development and commercial management have enhanced the company's ability to innovate, improve customer service and support future growth.
Today, Kaymed employs 250 people of 26 nationalities across its Bluebell and Kilcullen facilities, reflecting the diverse talent that continues to drive the business forward.
Looking ahead, Kaymed says it will showcase the next generation of sleep products at this year’s Bed Show, taking place at Telford International Centre on 22nd-23rd September: “Developed in partnership with Leggett & Platt, one special collection combines advanced foam technologies with the expertise of the world's leading spring systems manufacturer to deliver fresh thinking in sleep comfort and wellness.”
Find Kaymed on stand D30 in hall 2.
Pictured: Kayfoam’s operations team
