Accelerating Growth: DOW(TM) Predictive Intelligence Supports Expansion of Luuna(R) Mattresses

Rhea-AI Summary

Luuna Mattresses, a Mexican startup known for its 100% foam mattresses, has partnered with Dow to accelerate its expansion in Latin America. The collaboration leverages DOW Predictive Intelligence, a digital platform combining over 120 years of polyurethane formulations expertise. This technology has enabled Luuna to develop new foams in a single production test, significantly reducing development time and costs.

The platform's precision has supported Luuna's ambitious plans, including the development of Latin America's most advanced production center, targeting one mattress every 30 seconds. The partnership has also helped Luuna achieve 1% production scrap, supporting their sustainability goals while maintaining their position as Mexico's Best Rated Mattress.

Positive

• Successful implementation of DOW Predictive Intelligence platform reducing development time and costs
• Achievement of 1% production scrap rate
• Expansion capability to produce one mattress every 30 seconds
• Vertical integration improvement in Mexican market

Negative

• None.

Insights

Tech Expert

DOW's Predictive Intelligence platform represents a strategic advancement in materials science automation, leveraging AI to optimize polyurethane formulations. The platform's ability to analyze thousands of ingredient combinations in hours rather than weeks showcases meaningful operational efficiency gains. For Luuna Mattresses, this translates to reduced development costs, faster time-to-market and improved production efficiency with only 1% scrap rate.

The technology's impact extends beyond just speed - it demonstrates how digital transformation in traditional manufacturing can create competitive advantages. By enabling single-trial formulation success and supporting production capacity of one mattress every 30 seconds, this represents a significant manufacturing breakthrough in Latin America's mattress industry.

Manufacturing Analyst

The vertical integration strategy supported by DOW's predictive technology marks a pivotal shift in manufacturing efficiency. The reduction to single-production testing cycles represents substantial cost savings in raw materials, labor and energy consumption. Traditional foam formulation typically requires multiple iterations and test runs, each costing thousands in materials and operational expenses.

The ability to produce a mattress every 30 seconds (approximately 2,880 units per day) positions Luuna for significant market share growth in Latin America. This production rate, combined with the 1% scrap rate (industry average is typically 3-5%), indicates potential for higher profit margins and improved operational sustainability.

NORTHAMPTON, MA / ACCESSWIRE / December 30, 2024 / DOW
Pioneering an advanced sleep technology

Luuna^® Mattresses is a Mexican startup that offers a pioneering 100% foam mattress that can be vacuum compressed into a compact box. The brand's disruptive omnichannel marketing model and vertically integrated production process have made it one of the fastest growing brands in Latin America.

The exceptional quality of the brand's polyurethane foam mattresses has been endorsed by a Notary Public as the Best Rated Mattress in Mexico.

BUSINESS CHALLENGE

Developing a quality product to support business expansion

As it ramped up its ambitious expansion plans, Luuna^® intended to establish the most vertically integrated model in Mexico which would enable it to develop new foams quickly in response to market demand. To achieve this - it required the brand to find reliable suppliers who would be capable of efficiently delivering high-quality polyurethane formulations.

The reliability and stability of the collaboration was crucial to support Luuna^® during a rapid growth phase.

"We are grateful to work with Dow and to rely on Predictive Intelligence. Thanks to Dow, we have the confidence to pursue an aggressive expansion plan, whilst ensuring that we deliver quality and reliability to our customers."

- William Kasstan, Co-Founder and CMO, Luuna^® Mattresses

SOLUTION

Generating reliable, precise formulations - thanks to digital innovation

Since working with Dow, Luuna^® has benefited from DOW™ Predictive Intelligence, a digital platform that brings together over 120 years of Dow's polyurethane formulations.

"Predictive Intelligence is a virtual lab, powered by a unified global data platform for artificial intelligence models, which allows our product development scientists to instantly visualize, analyze, and model thousands of ingredients and properties, significantly reducing development times of new polyurethane formulations," said Sarah Eckersley, Vice President Research and Development, Dow Industrial Intermediates & Infrastructure. "It puts the customer at the center of our processes, enabling Dow scientists to search for the right formulation in days or even hours."

The precision of the formulation that DOW™ Predictive Intelligence delivers has enabled Luuna^® to successfully develop new foams -- allowing the company to offer a greater variety of mattresses -- in a single production test. This has drastically reduced development time, while lowering the associated costs. As a result, it enables the company to pursue its expansion goals, such as creating the most advanced production center in Latin America which is expected to produce one mattress every 30 seconds.

Fewer production trials also means avoiding emissions from additional trials. Luuna^® has reduced scrap to 1% in all production. These benefits help the company on its sustainability journey.

"At Dow, we are transforming the way we collaborate with our customers - combining our materials science expertise with cutting-edge digital technology to significantly improve product formulation and accelerate time-to-market," said Aylin Tame, General Manager, Dow Mexico. "The success of our collaboration with Luuna^® is evidence of the inherent possibilities of Predictive Intelligence."

Discover more about DOW™ Predictive Intelligence

About the article

This case study was developed by a cross-discipline team representing materials and market expertise across Dow, Inc. in collaboration with our customer, Luuna^® Mattresses. The Predictive Intelligence digital capabilities referenced in it have been developed by a team sponsored by Sarah T. Eckersley, Ph.D., R&D vice president of Dow Industrial Intermediates & Infrastructure.

Luuna^® is a trademark property of KSMV Capital, S.A.P.I de C.V.

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Contact Info:
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SOURCE: DOW

View the original press release on accesswire.com

FAQ

How has DOW Predictive Intelligence platform improved Luuna's mattress production?

DOW Predictive Intelligence has enabled Luuna to develop new foam formulations in a single production test, significantly reducing development time and associated costs while maintaining quality standards.

What production capacity will Luuna achieve with DOW's technology?

With DOW's technology support, Luuna's new production center in Latin America is expected to produce one mattress every 30 seconds.

What sustainability benefits has Luuna achieved through DOW's partnership?

Through the partnership with DOW, Luuna has reduced production scrap to 1% and minimized emissions by requiring fewer production trials.

How does DOW Predictive Intelligence accelerate foam formulation development?

DOW Predictive Intelligence uses artificial intelligence to instantly analyze thousands of ingredients and properties, reducing formulation development time from weeks to days or hours.