BK ITALIASofa-beds

Via Bergamo 66, 24047 Treviglio (BG)Telefono +39 0363 48971 Fax +39 0363 45917

info@bkitalia.com

BK ITALIA is a company specializing in the production of sofa beds.The BK ITALIA product is the result of different skills and professions that have managed to combine the concepts of rest and comfort through functional and high design solutions, creating essential furnishings for modern and traditional spaces capable of enhancing any home environment.

BK ITALIA

Operating in the furniture sector since 1977, the company has bet on the combination of technology and design since the very beginning, thanks to its production flexibility. BK ITALIA is, in fact, one of the few companies to manage the entire sofa bed production cycle: from the carpentry department, where the metal parts needed for the mechanisms are made, to the upholstery department, to the department where semi-finished items are assembled together.In addition, all the prototypes designed by architects are made in the BK ITALIA laboratories.Quality, timely deliveries, strong focus on ethics (no exploitation of child labor and environmental compatibility certificates) and a solid financial position are the characteristics that have made BK ITALIA a point of reference in the sector, on both the Italian and international market, in the private and professional sector.

ENVIRONMENTAL PROTECTION, SAFETY AND QUALITY POLICIES AND OBJECTIVES

The company, operating on the market since 1954, has always considered the quality of the finished product and of its components to be of primary importance, thus adapting the selection of raw materials for semi-finished products and of technologies available on the market to the new environmental protection and workers’ safety requirements.

The definition and planning of each phase of the production cycle is the result of choices that take into account compliance with the provisions on the subject of workers’ and environmental protection. Consequently, attention is paid both to aspects pertaining to internal raw materials transformation processes (management of production scrap, use of better products and technologies in terms of workers’ and environmental protection), and to the selection of suppliers of semi-finished goods who are aware of environmental policies.

There are five main types of product components (sofa/bed conversion mechanism, mattress, accessory frames, padding and lining), and they are basically made up of four types of raw materials: iron, wood, padding material (elastic foam polyurethane, natural feather) and fabric (mostly cotton).

GUIDELINES

Environment · use of raw materials and recyclable materials and materials of known origin · use of full recovery (electrostatic painting system with epoxy powder) or partial recovery (in-line greasing system with purification plant for the recovery of dirty solvent) systems · management of processing scrap according to well-defined and regulated procedures: the waste generated can be recovered as secondary raw material for almost all types (iron and wooden scrap, remnants of cotton fabric, paper and cardboard for packing) · selection of suppliers according to principles concerning issues of workers’ and environmental protection (certificates requested with regards to materials and productive cycles used)

Safety · production cycle managed according to instructions and procedures defined in the Safety document drawn up in compliance with regulations in force (Italia Law 626/94) and periodically updated · systems and machinery updated and with EC markings · specialized personnel updated through specific training courses · ordinary maintenance managed internally by suitably trained internal staff · defined emergency and fire-prevention plan

Quality · quality control (verifying the suitability of the product or semi-finished item) carried out by personnel in charge in every production department and in the warehouse upon the receiving of goods · production process monitored and checked at the computer level (phase advancement detected in real time by means of a bar code system) in every single sub-phase of the manufacturing and warehouse departments · personalized warranty certificate for each product with specifications on components and materials, utilization methods, safety regulations · selection of materials with excellent characteristics and qualities (see subsequent paragraph)

PRODUCTION CYCLE AND MATERIALS

Metal Carpentry

Complete and flexible department in which, thanks to the experience of its staff and constantly updated equipment, the machining and production of all metal parts needed to make the sofa-bed conversion mechanism are carried out. The department also guarantees the possibility to manufacture new frames (prototypes studied and designed by the company’s own research and development office) and to put in production mechanisms with special sizes requested by the customer Materials · use of raw materials of national origin · E220 quality steel, certified 2.2 and 3.1 according to standards EN 10204 · types according to standards EN 10305-3 and 5: · steel sections obtained from a cold-rolled strip with surfaces that can be painted or chromed (i.e. for visible parts and the structure of the spring of the mechanisms built with 30x30x2 mm and 0x30x1.5 mm section with slots for the insertion of slats) · steel sections obtained from a hot-rolled pickled strip (i.e. for load-bearing frame – round, square and rectangular sections from 60x40x2 mm up to 10x10x1.5 mm, always with a minimum thickness of 1.5 mm) · round, flat drawn elements in Fe360 (i.e. for the movement mechanism – flat 30x5 mm and supporting structures)

Metal carpentry phases

Cutting · automatic cutting by means of CNC machine of 10-15 q bundles of rods with bars 6 m long – programmable in three different cutting measures in continuous

Shearing · shears of different tonnage (from 30 q to 160 q) equipped with individual moulds and step processing for drilling, shearing, bending…

Degreasing · in-line solvent-based degreasing system by immersion with purification system for the recovery of dirty solvent

Welding · arc welding with metal under gas protection (MIG -Metal-arc Inert Gas type) with continuous filament that

guarantees a highly productive process; at the same time, the presence of inert gas allows for an operation without any waste · robotic welding stations (shielded anthropomorphous robots) that work on templates which offer univocal positioning of the individual pieces and a constant quality even for important work orders · manual welding stations equipped with templates identical to those used in the robotic stations

Painting · automatic electrostatic painting system with powder with automatic high-penetration guns that guarantee a protective film of a 70/80 micron minimum thickness on the painted piece · polyester mica powder paint, gun-barrel gray, for products exposed to the elements; · excellent resistance to corrosion · excellent resistance to atmospheric agents · excellent retention of shine and constant color over time · high mechanical characteristics, high elasticity

Assembly · positioning of the semi-finished products onto three-dimensional templates to guarantee constant assembly quality · riveting with pneumatic riveting machines coming from the aeronautical sector

Quality control · the quality control carried out at the end of each single phase, from the acquisition of raw materials to the finished carpentry product: sampling dimensional checks, static and material workability tests

Upholstery

Cutting · automatic cutting with CNC machine of fabric mattresses with cutting plans managed by an in-line software program · manual cut with electric cutter with automatic sharpener for special types of fabrics (flowered, striped, leathers)

Overcasting · use of technologically advanced sewing machines specifically suited for the type of sewing

Sewing · overcasting, single, double stitches, leather) equipped with personalized tables

Pre-upholstery · use of foam polyurethane, a raw material used both for the padding of pillows and of accessory frames (armrests and backrests) and in the padding of mattresses (whose structure consists of a series of steel springs) – supplied by manufacturing companies that guarantee the absence of chlorofluorocarbons (C.F.C.) · upon the customer’s request, supply of special materials with high resistance to flammability, through the addition of specially modified additives and raw materials (to satisfy the strictest international regulations on the subject of fire-prevention). · use of water or solvent-based gluing systems depending on the combination of materials to be glued together (wood, iron, polyurethane)

Lining assembly · use of ergonomic tables and flexible stations depending on the type of assembly to be carried out · lining phase entrusted to the artisan skills of specialized and expert workers

Woodworking

Materials · use of material without any surface treatments and verification that the origin of the wood is the non-destructive type · types used:a. solid pinewood for internal support structures b. poplar plywood thickness 10/18 mm for front elements and side closings of the armrest frames c. phenolic OSB panels 18.5 mm resistant to humidity for the armrests support structures d. wooden fiber 3mm thick for closings with special shapes

Assembly · use of different fixing typologies at the same time · shaped groove · gluing with vinyl glue · fixing with metallic points Ø1.1 mm

Mattresses department

Types · possibility to fit different types of mattresses on sofa beds with standard dimensions (height 15 cm):a. orthopedic spring mattresses b. polyurethane mattresses with varying densityc. mattresses with Memory foam d. box spring mattresses for single sofa beds

SPECIAL PRODUCTIONS

Fireproof type-approved products · collection of products equipped with type-approval for fire prevention issued by the Ministry of the Interior (fire resistance class 1 IM) and specific certifications on materials used (standards EN 1021)

Custom-made products · possibility to manufacture custom-made products and various compositions

RESEARCH AND DEVELOPMENT

The company’s own internal research and development department, fully operational operative and in constant activity, is capable of turning any of the designers’ new ideas and suggestions into a reality in a short period of time

Research and development office · study of the movement mechanisms using last-generation software (Inventor 2008 by Autodesk, Autocad 2008) that kinematic movements (three-dimensional rototranslations) to be studied and developed and of static and dynamic applications for the analysis of the stress limit states

Prototypes laboratory · laboratory equipped with high-precision equipment (lathe, milling cutter, column drill, etc.) used to manufacture special custom-made pieces to be assembled and tested on the prototypes

Testing department · department in which materials and products are tested by subjecting them to continuous and programmable work cycles with motors applied to the mechanisms

The new generation

The headquarters

Materials

Welding

Painting

Upholstery

Mattress / Padding

Wood Work

Storage

Assembly

Delivery

Supplies for Hotels period 2003 – 2006

continent nation hotel Africa Benin 1 Egypt 1 Ethiopia 1 Ghana 1 Madagascar 1 Morocco 2 Nigeria 2 Reunion 1 Senegal 1 Total Africa 11 North America Canada 1 Total North America 1 South America Chile 1 Total South America 1 Asia Saudi Arabia 1 China 2 Lebanon 1 Singapore 1 Turkey 1 Total Asia 6 Europe Andorra 1 Austria 1 Belgium 6 Cyprus 2 France 155 Germany 13 Great Britain 44 Greece 2 Italy 40 Lithuania 1 Luxemburg 3 Montecarlo 2 Nederlands 11 Poland 5 Portugal 1 Czech Rep. 3 Romania 1 Russia 2 Spain 12 Switzerland 7 Ungheria 4 Total Europe 316 Overall Total 335

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