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Mattress Manufacturing / Futon Mattress Manufacturing

Tuesday, June 14, 2016 11:04:10 AM America/Los_Angeles

Mattress Manufacturing

Garnet Machine

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.

manufacturing-garnet-small carding-machine

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.

The Futon Shop began in 1976, manufacturing every one of their mattresses locally in their San Francisco Factory. Today, our operation is tucked away in a 30,000 square foot factory located at 2150 Cesar Chavez St., between, Dogpatch, Potrero Hill, and Mission Neighborhoods, of San Francisco. With so little manufacturing in northern California, The Futon Shop is one of San Francisco's oldest and largest manufacturers of mattresses and high quality futons. The Futon Shop is a vertically integrated retailer that manufacturers chemical free and eco-friendly mattresses from start to finish. They purchase raw cotton and wool from local farmers and process it on site.

What does this mean for the consumer? We are the manufacturer. There is no middleman. This way we can bring expensive, natural and organic ingredients affordably into each mattress and futon we handcraft and offer huge savings and discounts to you. The Futon Shop has made chemical free living affordable for everyone, because we believe everyone deserves the choice to sleep healthy. Today, it is not only “you are what you eat,” but "you are where you sleep" or in other words "you are where you live." Farm-to-bedroom brings locally made, natural and healthy furniture into America’s homes. In today’s fast paced world the bedroom is often overlooked, although more time is spent in bed then on any other piece of furniture in a home.

  • Click to learn more about Federal and state flammability laws for fire retardants in mattresses and cushions.
  • Click to learn more about chemical free mattresses. (all are fire retardant free) Please join in the fight against harmful and carcinogenic chemicals in your home and buy local and handmade sofas without chemicals for your home.

  • Click to learn more about Organic Cotton.
  • Click to learn more about Natural Virgin Wool.
  • Click to learn more about Natural Latex.

  • Click if you want to know the requirements of what makes a mattress organic
  • Click if you want to read why organic materials in mattresses are better
  • Click to browse through some great organic cotton mattresses.

  • Click to read The Futon Shop Warranty.
  • Click to see The Futon Shop Locations.
  • Click to read about The Futon Shop's strive toward Eco-Consciousness.

  • Click to read about the Farm to Bedroom Movement.
  • Click to read the dimensions of all mattress sizes.
  • Click to read about mattress lifespans.



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    The Futon Shop a family owned company since 1976 maintains a high level of Eco-Consciousness to strive for a healthier future for our planet and our country. We work tirelessly towards bringing the best organic cotton and eco-friendly futons, sofa beds & chemical free furniture options for the health and comfort of our customers