Flexible Air Caster Solution Boosts Output in a Growing Modular Factory
Maat Feeling Home Scales Modular Production with Aerofilm Systems Air Casters
Maat Feeling Home operates in a production environment where efficiency, flexibility, and space utilization are critical. With rising demand for modular housing and a fixed factory footprint, the company faced a clear challenge: increasing production capacity without expanding floor space. The shift toward line-based manufacturing added complexity, requiring smooth and adaptable internal transport between two production halls.
In collaboration with Aerofilm Systems, Maat implemented a custom air caster transport solution tailored to its modular production process. The system enables safe, controlled movement of modular units of varying sizes and weights, integrates seamlessly into the production flow, and removes internal transport as a bottleneck.
This case study highlights how a flexible and practical transport solution helped Maat Feeling Home scale output from 300–400 to 500–600 modules per year, within the same surface area. Showing how smart internal logistics can drive efficiency, improve flexibility, and support sustainable growth in modular construction.
About Maat Feeling Home
Maat Feeling Home is a well-established, family-owned manufacturer of modular and recreational housing, headquartered in Sliedrecht, the Netherlands. With over 50 years of experience, the company has built a strong reputation for craftsmanship, reliability, and high-quality prefab construction for both recreational and permanent living solutions.
Maat Feeling Home manages the full process in-house, from engineering and production to project coordination, ensuring consistent quality control and smooth delivery. The homes are built in the company’s facilities in Sliedrecht and leave the factory only when fully finished, enabling efficient on-site placement and a true turn-key experience for customers.
With a broad product range and modular units that vary in size, layout, and weight, Maat operates in a market that demands both speed and flexibility. Continuous improvement and innovation in production and internal logistics remain key priorities, helping the company optimize space, increase throughput, and stay competitive in the fast-evolving modular construction industry.
At the same time, Maat manufactures a wide variety of modular units with differences in dimensions and weight. Any transport system therefore needed to be highly flexible, safe to operate, and easy to integrate into daily production operations.
Maat was looking for a system that could:
- Handle different module sizes and weights
- Support line-based production
- Enable efficient movement between production halls
- Integrate seamlessly into the existing manufacturing process
The Challenge
Maat Feeling Home set out to increase production capacity without expanding its factory footprint. The objective was straightforward: produce more modules per year on the same surface area. To support this growth, the company redesigned its manufacturing process into a line-based production setup, enabling modules to move step-by-step through the factory in a structured flow.
This transition introduced a new internal logistics challenge. As part of the production sequence, modular units now had to be transported smoothly and reliably between Factory A and Factory B, without disrupting throughput or requiring excessive handling time.
The Solution
Maat found the solution in air caster technology from Aerofilm Systems. From the outset, the collaboration focused on delivering a practical and flexible transport approach, tailored to Maat’s specific production requirements and daily workflows.
Following the order, an Aerofilm application specialist visited the site to support the implementation and ensure a smooth start-up. Working closely with the Maat team, the system was configured and fine-tuned to integrate seamlessly into the line-based production process.
The specialist remained on-site until the solution performed exactly as intended, providing a reliable handover and giving the production team full confidence in daily operation.
The air caster solution enables Maat to move modular units smoothly, safely, and with minimal effort across the factory floor. Regardless of size or weight. Its built-in flexibility makes the system ideally suited to Maat’s broad product range and continuously evolving production layout.
As a result, internal transport is no longer a constraint, but a reliable and fully integrated part of the line-based manufacturing flow, supporting both efficiency and scalable production.
Beyond the numbers, the solution delivered clear operational benefits:
- A smoother, more efficient production flow
- Greater flexibility for handling different module sizes and weights
- Reliable internal transport between production halls
- A future-ready setup that supports continued growth
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