October 26, 2020 Mattress Manufacturing

Processes, materials, quality control and the future.

Not all things are created equal, and that includes mattresses. Nowadays, there’s more to mattresses than what meets the eye and consumers know this. Gone are the days when people think that a mattress is just a one-size-fits-all piece of furniture. On the contrary, consumers have now become so particular about the comfort or support that a mattress could give them at any time.

The mattress industry is in the upswing, thanks to the increasing demand from a variety of sectors including the hospitality and the health sectors. Then there’s the booming real estate sector leading to an increasing number of homeowners looking for affordable mattresses that will fit their budget. Even the home furnishing sector is not far behind since there is also an increased demand for bed linens, covers and pillowcases.

The process of making mattresses

The mattress has come a long way from the 1850s when uniform springs were used in mattress upholstery, and the 19th century when the springs were stabilized resulting to a more resilient but firmer mattress. With millions of mattresses sold all over the world every year, manufacturers continue to find ways to make use of modern technology to make the process of making mattresses more cost-efficient. A lot of effort went into the making of the innerspring for the mattress as it was considered the bed’s core.

This technical process was very time-consuming that most manufacturers either subcontract the innerspring or just purchase them from a specialized company. In most cases, the real work begins once the innersprings are received. Lately though, there has been a competition between the spring and the foam mattresses. The foam mattress, specifically those made with very good foam quality, has gained popularity in the recent years thanks to its ability to reduce the sleeper’s pressure points accordingly by up to 80%.

Much effort goes into determining the cushion layers of the mattress as it will determine how supportive or comfortable the mattress will be. Of course, a lot of thought goes into the process of making the outside cover to make the mattress a thing of beauty.

Materials

The materials that make up your mattress will determine your quality of sleep. You may fall in love with the exterior of your mattress at first sight, but you will know later on that what matters most is what is inside the mattress. Whether you want to sleep on the clouds or on a hard surface to get more support, you will be better off knowing what’s inside your mattress. Here are some of the most common mattress materials used by the manufacturers:

• Foam
  -the type of foam used in your mattress will help provide relief to your pressure points and regulate your temperature. Aside from memory foam which has become popular among those who bask in restful slumber, you can also opt for viscoelastic foam, polyurethane foam, and gel memory foam among others.
• Polyester Batting
  -this material is used for the filling for pillow tops and mattress covers
• Wool
  -this is a water-resistant insulator that can give your mattress extra padding
• Cotton
  -this breathable material can add softness to the mattress
• Steel Coils
  -provides good support for the mattress

Quality Control

You will spend at least a third of your life sleeping or just resting on your mattress so you better be sure that it is safe and has passed quality assurance. Every manufacturer worth his salt must ensure that the mattresses only come out of the factory once they have passed the quality test. This is a standard followed by the mattress industry and should never be compromised not only to keep the customers satisfied but also safe.

Before you choose a mattress, make sure that the manufacturer has technicians that checks the mattresses for any defect. A company with an established assurance program will be able to minimize defects and thus earn more in the long term. There should be inspections and quality control in each stage of the mattress manufacturing.

Future of mattresses

Mattresses today are no longer just a place to catch some z’s or a shut-eye. Research has shown the important relationship between your sleeping environment and quality of sleep. Consumers who lead very busy lives are no longer taking quality sleep for granted, and are now more critical about the construction of their mattresses.

Apparently, they have discovered that there is an ideal mattress for every one and that it is no longer just a furniture that fits all. The consumer’s weight, height, and sleeping preference or position all affects the quality of sleep. There is a specific mattress that will suit a person who is on the heavy side, sleeps on his back or stomach, or someone who sleeps hot.

Despite the advancements in mattress technology, manufacturers and sleep scientists are in a mad rush to come up with new technologies that will help build better mattresses for consumers. This is not surprising at all considering that the world market for mattresses is expected to be worth more than $43 billion in the next five years. Marketers are confident that the robust demand for mattresses in China and other emerging and developing countries will translate to a better market for the industry.

Online mattresses are expected to continue to be in great demand, with over 175 companies in the online mattress sector. The number of mattresses being purchased online is also on the rise and this was partly attributed to a changing buyer’s demographic. Research shows that the millennials have somehow created a trend in mattress buying as they are replacing their beds more often. And as this generation increases its purse power, mattress manufacturers are expected to take their campaigns on the digital platform.

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