Comprehensive Guide to OEM Mattress Production Processes
Detailed Steps in Mattress Production
You’re in the business of importing sofa beds, and we understand that time is a crucial factor for you. This guide will help you understand the timeline of each stage in the process—helping you plan better, satisfy your customers, and manage your finances effectively.
Step 1: Designing the Mattress
Our process begins with designing the mattress to meet specific customer requirements.
Step 2: Quilting
The top fabric layer is quilted with padding materials for added comfort.
Step 3: Fabric Cutting
Precisely cutting the fabric ensures a perfect fit for all mattress components.
Step 4: Spring Assembly
High-quality metal springs are assembled to provide durable support.
Step 5: Applying Glue
Eco-friendly adhesive is used to bond the layers without any harmful fumes.
Step 6: Cotton Layer Application
Layers of cotton are added for extra cushioning.
Step 7: Edge Taping
The edges are securely taped to maintain the mattress’s shape and durability.
Step 8: Compression and Roll Packing
The mattress is compressed and roll-packed for efficient shipping.
Step 9: Quality Testing
Every mattress undergoes rigorous quality checks before packaging.
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Looking to expedite your monthly container orders of mattress? Contact us now for expert guidance on compressing lead times without sacrificing quality.
Packaging Methods for New Mattresses
Our mattresses are vacuum-sealed, compressed, and roll-packed in sturdy boxes, ensuring they remain protected during transit. This packaging method also makes it easier for customers to handle and unbox their new mattresses.
Common Raw Materials Used in Mattress Manufacturing
- Foam: Polyurethane foam is widely used for its affordability and durability.
- Cotton: Natural cotton provides softness and breathability.
- Coir: Coir fiber adds firmness and natural ventilation.
- Latex: Natural latex offers superior comfort and resilience.
Common Pitfalls and Solutions in OEM Mattress Manufacturing
- Using Low-Quality Foam: Ensure the foam density is high to avoid sagging.
- Thin Metal Springs: Use thicker metal wires for longer-lasting support.
- Inconsistent Sizes: Maintain strict quality control to ensure accurate mattress dimensions.
- Harmful Adhesives: Opt for eco-friendly adhesives to avoid unpleasant odors and health risks.
- Bonell vs. Pocket Springs: Choose pocket springs over bonell springs for better motion isolation.
Product Quality and Certifications
- EC1907/2006, BS7177, 16CFR, Crib 5, CertiPUR-US, and EN BS5852
Our mattresses are certified to meet international standards, including EC1907/2006, BS7177, 16CFR, Crib 5, CertiPUR-US, and EN BS5852. These certifications ensure our products are safe, durable, and environmentally friendly.
FAQs
Get instant answers to your queries about our Boucle Bed Frames. This section is tailored to provide clarity on all your commercial questions.
The production process includes designing, quilting, fabric cutting, spring assembly, applying glue, cotton layer application, edge taping, compression and roll packing, and quality testing.
Our mattresses are compressed, vacuum-sealed in a thick layer of plastic, and then folded and rolled up in a thinner layer of plastic, making them easy to transport and handle.
Common materials include foam, cotton, coir, and latex. Foam, especially polyurethane foam, is the most widely used due to its affordability and durability.
Our MOQ for mattresses is 40 sets per size and color. We are flexible and can discuss specific requirements based on your needs.
Yes, we offer customization options for mattress thickness, firmness, fabric, spring type, and packaging. Please contact us with your specific requirements.
Our mattresses are certified to meet international standards, including EC1907/2006, BS7177, 16CFR, Crib 5, CertiPUR-US, and EN BS5852.
We can produce a sample within 7 days. The sample fee is $100, which will be deducted from the total order amount if you place a large order.
Our typical lead time for bulk orders is 30-40 days after receiving the deposit and confirming all details.
