Driving Efficiency in Foam Conversion: How Peak Converters Enhanced Bonding with APER and Simalfa

For foam converters supplying the upholstery industry, consistency, efficiency and precision are critical to delivering high-quality products at scale. For Peak Converters, a business working with both large and small upholstery manufacturers, improving their bonding process became a key operational priority.

Managing Director Mike Crowshaw first identified a potential solution after encountering APER bonding systems at an industry exhibition. The technology immediately stood out as an opportunity to modernise their adhesive application process — moving away from traditional spray methods towards a more controlled, automated approach.

A key challenge with manual spray application is what Mike describes as the “north pole effect” — a common issue where excessive adhesive builds up in certain areas due to inconsistent application. There is often a misconception that more glue leads to a better bond, when in reality it can create inefficiencies, waste, and inconsistent results.

By installing an APER bonding system and integrating Simalfa adhesives, Peak Converters were able to completely transform this process.

“The machine does the application,” explains Mike. “There’s no glue build-up around the product, and the bond is far more consistent.”

The shift away from manual spray guns has delivered several immediate benefits. Overspray — a frequent issue in traditional bonding environments — has been eliminated, creating a cleaner and more controlled production setting. At the same time, the system ensures a uniform adhesive layer across every product, significantly improving quality consistency.

Operational efficiency has also improved. Previously, foam sheets would need to be transported to a spray booth for adhesive application. With the APER system, materials now pass directly through the machine as part of the production flow. This streamlined process reduces handling time, saves labour, and increases throughput.

“Sheets aren’t going to a spray booth anymore — they go straight through the machine. It saves both time and labour,” Mike adds.

The installation process itself was equally impressive. Completed in just five days, the transition was seamless, allowing Peak Converters to quickly realise the benefits without prolonged disruption to operations.

Supporting this project throughout was Handy Limited, acting as the UK agent for both APER and Simalfa. Their role extended beyond supply, providing ongoing guidance and technical insight at every stage of the journey.

“Handy have been there every step of the way,” says Mike. “They were always included in communications, offering insight and sharing their experience to support the project.”

This close collaboration ensured that Peak Converters could make informed decisions, optimise their setup, and fully leverage the capabilities of the new system.

The relationship between the two businesses was already well established, with Peak Converters regularly sourcing smaller components such as silicone spray and other consumables from Handy Limited. This existing partnership helped create a smooth and trusted pathway for adopting more advanced solutions.

Today, the integration of APER machinery and Simalfa adhesives has positioned Peak Converters with a faster, cleaner and more consistent bonding process — reinforcing their ability to meet the evolving demands of the upholstery sector.