Mattress Layer Anatomy & OEM Engineering.
De-risk your private label mattress procurement. Understand coil gauges, foam densities (25D-35D), comfort quilting, and fire compliance (BS 7177 / 16 CFR 1633) to optimize container loading and landed unit economics.
Pre-stressed barrel coils with dual-edge reinforced perimeter.
Zone-tailored pocket springs for localized contouring.
Zero-filler PU, memory foam, and natural latex options.
Optimized for e-commerce parcel and 40HQ container yield.
Low-VOC adhesives & strict fire retardant specifications.
The 4 Critical Layers of a Commercial Mattress.
Every commercial specification is built from top fabric down to foundational base foam. Adjust each layer to target retail price points and channel durability.
Quilted Cover & Ticking Fabric
High-grammage knitted jacquard (280g-450g), anti-pilling, cooling bamboo silk, or flame-retardant treated polyester fabric quilted with 1.5-3cm high-density hypersoft foam.
Comfort Transitional Foams
40D-50D Gel Infused Memory Foam for thermo-regulation or 2.5-5cm Natural Latex for responsive rebound. Prevents pressure hot spots on hips and shoulders.
Pocket Spring Support System
Individually encased barrel springs in ultrasonic-sealed non-woven fabric. Minimizes partner disturbance and prevents center roll-together. 3-zone, 5-zone, or 7-zone ergonomic zoning available.
High-Density Base Foam & Non-Slip Underside
25D/30D high-density support foam foundation (2-4cm) paired with a heavy-duty polyester non-slip dotted base fabric to prevent shifting on slatted bed bases.
Support Core & Foam Density Guide.
Select the core type that best matches your target market's shipping cost restrictions, firmness expectations, and warranty requirements.
Independent Pocket Springs
Each spring is sealed in spunbond fabric pockets, moving independently. Highest point-elasticity, zero motion transfer, ideal for rolled e-commerce boxing.
- ✓ Motion Isolation: Near-zero partner vibration.
- ✓ Compression: Outstanding roll-pack expansion recovery.
- ✓ Wire Gauge: 1.8mm - 2.2mm high-carbon manganese wire.
- ✓ Best For: UK, Germany, France, Mid-to-High Retailers.
Traditional Bonnell Springs
Hourglass-shaped coils interconnected with helical wire. Rigid structural support, high airflow, and competitive FOB cost for budget lines and institutional contracts.
- ✓ Support Feel: Very firm, traditional bouncier feel.
- ✓ Landed Cost: 20-35% more economical core unit.
- ✓ Roll Packaging: Flat-packed or light roll-compressed only.
- ✓ Best For: Student housing, rental suites, budget promotional SKUs.
UK & Continental European Size Matrix.
We engineer mattresses to exact market dimensions to avoid fitting friction with bed frames, gas lift bases, and fitted sheets.
| Target Region | Nominal Size Label | Dimensions (W × L mm) | Typical Thickness | Est. 40HQ Loading (Roll-Pack) | Action |
|---|---|---|---|---|---|
| UK & Ireland | Single | 900 × 1900 mm | 200 - 250 mm | ~720 - 800 pcs | |
| UK & Ireland | Small Double (Queen) | 1200 × 1900 mm | 220 - 280 mm | ~540 - 600 pcs | |
| UK & Ireland | Double UK Hero | 1350 × 1900 mm | 220 - 300 mm | ~480 - 540 pcs | |
| UK & Ireland | King | 1500 × 2000 mm | 250 - 320 mm | ~420 - 480 pcs | |
| UK & Ireland | Super King | 1800 × 2000 mm | 250 - 320 mm | ~340 - 390 pcs | |
| Continental EU | EU Single | 900 × 2000 mm | 180 - 240 mm | ~700 - 760 pcs | |
| Continental EU | EU Double EU Hero | 1400 × 2000 mm | 200 - 280 mm | ~460 - 520 pcs | |
| Continental EU | EU King | 1600 × 2000 mm | 220 - 300 mm | ~390 - 440 pcs |
Consolidate Upholstered Beds + Compressed Mattresses.
Maximize 40HQ cube utilization by pairing KD storage bed frames (2 boxes/unit) with vacuum-rolled mattresses in individual shipping cartons.
Comprehensive OEM Customization Scope.
From stitch patterns and woven corner labels to full drop-ship mail-order carton packaging.
Ticking Fabrics & Quilting
Select from 100+ knit patterns, cooling ice-silk, organic cotton, 3D mesh breathable sidewalls, and anti-slip backing fabrics.
Configurable OptionFirmness & Internal Layers
Calibrate firmness from Soft (H2) to Extra-Firm (H4) by tuning wire gauge, zone layouts, and latex/memory foam comfort layers.
Configurable OptionBranding & Trims
Woven corner satin badges, embroidered handle logos, printed tape edges, and custom law-tag / fire compliance labelling.
OEM BrandingPackaging & Mail-Order Box
Vacuum compressed roll-pack in reinforced 5-layer kraft cartons. Full-colour litho-printed boxes or branded kraft printing.
E-commerce ReadyFire & Chemical Compliance
BS 7177 (Low / Medium Hazard Crib 5), 16 CFR 1633 (US), REACH low formaldehyde, and OEKO-TEX Standard 100 foam testing.
Certified ComplianceSample Prototyping
Physical mattress samples delivered in 7-10 days with complete material swatches and spring firmness confirmation sheets.
Rapid PrototypingPopular Mattress Base Configurations.
Pre-engineered base models ready for quick sample development and immediate 40HQ container production.
Double-Sided Hybrid Mattress
Mattress Sourcing & Procurement FAQ.
Key questions regarding roll compression warranties, minimum order quantities, and UK/EU fire testing protocols.
How long can compressed roll-packed mattresses remain boxed? ▼
What are the typical MOQs for private label mattresses? ▼
Can you provide BS 7177 and UK Fire Safety test reports? ▼
What is the standard lead time for sampling and mass production? ▼
Ready to Engineer Your Next Mattress Hero SKU?
Connect directly with our factory engineering team. Send your target retail price, layer requirements, and destination country to receive a comprehensive FOB quotation and 40HQ loading plan.