Private-Label Mattress Engineering

What Can You Customize in a Private-Label Mattress?

From multi-zone pocket coil gauges and foam density layering to BS 7177 fire safety and roll-packed e-commerce cartons. Calibrate every layer for your retail channel, landed cost targets, and destination market standards.

✓ Vacuum Roll-Packed

✓ BS 7177 & REACH Fit

✓ Bed + Mattress 40HQ Mix

Explore Configurable Layers ↓

Configurable Core

Multi-Layer Hybrid Spec

OEM / ODM Ready

Top Quilting & Cover

Custom Knit / Tencel

Anti-pilling, cooling yarn, custom stitch pattern & zipper

Comfort & Transition Foam

25D - 45D Density

Gel memory foam, natural latex or breathable wave foam

Support Core System

3 / 5 / 7 Zones

Individual pocket springs (1.8-2.3mm) or high-resilience base

Edge Encasement & Base

Reinforced Perimeter

Anti-slip dotted base, dual edge coil row or foam wall

Sample Prototyping: 5-7 Days Testing: Roll-Compression Passed

Spring Core Pocket / Bonnell

Comfort Foam Gel / Latex / HD

Firmness Rating H1 Soft - H5 Firm

Cover Fabrics Knit / Tencel / Bamboo

Packing Method Roll-Pack in Box

Fire Compliance BS 7177 / 16 CFR

Component-By-Component Engineering

6 Core Areas You Can Customize for Your Brand

Every mattress program is built around specific retail positioning, packaging volume constraints, and margin targets. Review what is standard, configurable, and engineered on demand.

Support Engine

Spring & Core System

Engineered for roll-pack compression rebound stability and targeted spinal alignment.

▸ Pocket Springs: 1.8mm - 2.3mm wire gauge, barrel / cylindrical shape
▸ Zoned Support: 3-zone, 5-zone, or 7-zone body pressure distribution
▸ Bonnell / Continuous: High-durability traditional coil systems for volume contracts
▸ Full Foam Core: High-resilience base foam (28D-35D) for zero-motion transfer

MOQ: From 30-50 pcs/size

Feel & Pressure Relief

Foam & Comfort Layering

Formulate precise tactile comfort by combining foam densities and thermal properties.

▸ Gel-Infused Memory Foam: Heat-dissipating contouring comfort (40D-50D)
▸ Natural / Synthetic Latex: Pin-core breathable responsive bounce (65D-75D)
▸ Wave / Convoluted Foam: Airflow ventilation & targeted zoning transition
▸ High-Density Support Foam: 25D, 30D, and 35D firmness foundational layers

Certifications: CertiPUR / OEKO-TEX

Sleep Experience

Firmness & Dual-Sided Specs

Tune firmness precisely to market preferences (e.g. Medium-Firm for UK/EU retail).

▸ H1 to H5 Firmness Grading: From Plush Pillow-Top to Orthopedic Extra-Firm
▸ Dual-Sided (Flippable): Summer (Cooling) / Winter (Cozy) dual firmness
▸ Split-Firmness (King/Super King): Medium on Left, Firm on Right for couples
▸ Mattress Height: Configurable from slim 15cm (bunk beds) to luxury 35cm

Calibration: Physical Swatch Lab Approved

Tactile Aesthetics

Fabrics, Quilting & Edges

Visual appeal and skin-contact softness that convert online impressions into sales.

▸ Fabric Types: Jacquard double-knit, Tencel, Bamboo, Organic Cotton, Antibacterial
▸ Quilting Patterns: Geometric wave, deep diamond tuck, euro-top channel stitching
▸ Cover Construction: Tape-edge sealed or 360° washable zippered removable cover
▸ Side Border: Premium upholstery velvet, corduroy, breathable mesh side walls

Weight: 220g/m² to 550g/m² Knitted Options

Brand Identity

Private Label & Trims

Turn factory OEM into your proprietary brand with fully coordinated custom trims.

▸ Corner Embroidery: High-definition multi-thread brand logo placement
▸ Woven Ribbon & Piping: Custom-matched tape-edge trim color and printed branding
▸ Side Handles: Reinforced horizontal / vertical fabric handles with stitch accents
▸ Law Labels & Manuals: Compliant fire rating labels, unboxing booklets & warranty cards

Branding Package: 100% Client-Owned

FOB & Courier Fit

Roll-Pack & Container Loading

Engineered package dimensions to minimize last-mile surcharges and maximize 40HQ container count.

▸ Mattress-in-a-Box: Heavy-gauge vacuum compression + automated roll packing
▸ Carton Customization: 5-layer corrugated mail-order box with full-bleed flexo print
▸ Flat-Compressed Pallet: Optional high-density flat stacking for bulk retail buyers
▸ Mixed-Container Loading: Combine roll-pack mattresses with KD bed frames in one 40HQ

Drop-Test: ISTA 1A / 3A Compatible

Standardized & Custom Tooling

Tailored Sizing for UK, European & US Retail

Avoid dimensional return rates with factory spring molds and foam CNC cutting built to precise national standards. We support both metric and imperial specifications.

💡 Bed Frame + Mattress Tolerance Fit

Our mattresses are engineered with standard ±10mm manufacturing tolerances to pair seamlessly with our upholstered and gas-lift bed frame interior inner dimensions.

Popular Market Dimension Matrix FOB Container Reference

Market / Standard	Size Name	Dimensions (W × L mm)	Est. Roll 40HQ Qty
UK Standard	Single / Double	900×1900 / 1350×1900	600 - 850 pcs
UK Standard	King / Super King	1500×2000 / 1800×2000	380 - 520 pcs
EU Standard	Single / Double	900×2000 / 1400×2000	580 - 800 pcs
EU Standard	Queen / King	1600×2000 / 1800×2000	360 - 490 pcs
Custom / Hotel	Bespoke Project	Any Width / Length	Calculated per spec

* Actual 40HQ container quantities depend on mattress height (20-32cm) and box packaging dimensions.

Evidence Before Promises

Strict Fire & Chemical Compliance for Global Entry

Never risk container customs holds or retail safety recalls. We match specific foam additives, barrier fabrics, and test documentation to your country's statutory regulatory regime.

UK BS 7177 Low / Medium Hazard (Crib 5)

Compliant with UK Furniture and Furnishings (Fire) (Safety) Regulations. BS EN 597-1/2 cigarette & match testing for domestic and hospitality contracts.

EU REACH & GPSR Chemical Limits

Strict formaldehyde release limits (<0.062 mg/m³), zero harmful phthalates, and OEKO-TEX Standard 100 Class I/II textile certs.

16 CFR Part 1633 / 1632 Flammability

Open flame test compliance using certified fiberglass-free FR rayon / inherent FR modacrylic barrier knit socks.

Factory QC & In-House Testing

Every production batch undergoes verifiable mechanical stress and compression recovery audits.

100,000+

Rollator Durability Cycles

ASTM F1566 hex-roller simulated 10-year lifespan load test

72-Hour

Vacuum Compression Test

Full thickness and edge rebound verification post-unboxing

100%

Coil Heat-Tempering

High-tensile carbon steel anti-sagging thermal hardening

ISTA 3A

Package Drop Test

Carton corner and drop-edge impact protection for D2C transit

Need official test report references?

Structured Commercial Pipeline

How We Take Your Mattress from Brief to 40HQ Loading

A disciplined stage-gate approval process ensures the physical sample matches the signed specification and repeat production batches.

Spec Definition

Confirm target retail price, market dimensions, spring gauge, foam type, and box packaging limits.

Rapid Prototyping

Physical sample produced within 5-7 days with client-selected knit fabric and comfort layers.

Compression Audit

Sample undergoes vacuum roll-pack test to verify rebound height and edge integrity post-unboxing.

PI & Sealed Reference

Final golden sample signed off; detailed spec sheet locked for mass production QA benchmarking.

FOB 40HQ Loading

Batch production (30-day standard), inline QC inspection photos/videos, and direct container loading.

Clear Before Quoting

Mattress Sourcing FAQ

Have project-specific questions regarding MOQ flexibility, mixed containers, or roll-pack warranties?

What is the typical MOQ for custom private-label mattresses? ▼

Standard trial orders start around 30 to 50 pieces per size for existing spring/foam configurations. For completely custom knitted jacquard fabric patterns with your brand woven into the yarn, fabric mills typically require a 300-500 meter run. We can also use high-end in-stock fabrics paired with custom embroidered labels to keep trial MOQs low.

Can we combine mattresses and upholstered bed frames in one 40HQ container? ▼

Yes, mixed-container ordering is one of our primary B2B strengths. Because our mattresses are vacuum roll-packed into compact cartons, they can easily be loaded alongside flat-packed upholstered gas-lift storage beds, allowing you to test full bedroom sets with minimized inventory holding risk.

How long can the mattress remain compressed in the roll-pack box? ▼

Using our high-resilience heat-tempered pocket coils and virgin 30D+ density comfort foam, our mattresses can remain compressed for up to 3 to 6 months without permanent thickness or corner deformation. For optimal consumer unboxing experience, we recommend unboxing within 90 days of receipt.

How are sample orders and physical swatch approvals handled? ▼

Mattress samples are completed within 5 to 7 days upon specification confirmation. We can express-courier full physical cut-section corner prototypes or complete sleepable sample units for testing, alongside fabric swatch cards for cover sign-off. Sample fees are fully creditable against subsequent 40HQ container orders.

Factory Direct OEM / ODM

Ready to Configure Your Mattress Line?

Send your target dimensions, comfort feel requirements, and container assortment plan. Receive a detailed FOB specification breakdown and loading calculation within 24 business hours.