What Is The Mattress Manufacturing Process?

The image here is a cotton gin that is used to clean cotton fiber and layer it into felted bats. One of these machines can be found at The Futon Shop Headquarters in San Francisco, where all of their natural fibers are felted. The materials of organic wool, natural wool, natural cotton and organic cotton are felted into comfort layer batting. These bats are then used in mattresses and futons.

Mattress and Futon manufacturing is an ancient skill, yet new technology has allowed great innovation and higher quality products. The ability to combine new materials into mattresses and futons, roll them up and ship them in a box to customers’ homes is a reality. This technology does have pros and cons. The main pro is cost effectiveness. When roll packaged, the mattress can ship quickly and inexpensively and is more easily handled for installation into your home. The main con is that the new technology is ideally suited for packaging foam. This has caused market has become saturated with foam mattresses. The traditional mattress craftsmen are being replaced by foam manufacturers who ship out foam mattresses. Companies such as Casper, Saatva, Tuft & Needle, Purple Mattress, Tulo, Loom & Leaf, Leesa, Nectar to name a few all sell basically the same foam mattress with a cover. The brands farm out manufacturing to the polyurethane foam companies who are manufacturing the foam. The foam company's use petro-chemical bi-products from refining gasoline to create different types of foams including memory foam and gel foam. There is a flood of these mattresses in the market, as well as China imports like “Keetsa”, a major con indeed.