How a mattress is made
Completing the mattress
• 5 The closing operation is of one of the most highly skilled and critical procedures in the entire process. It is done with a movable sewing head that is mounted on a track. Tape edge operators manually feed the top, bottom, and side panels and a heavy duty binding tape into the sewing machine as it moves around the mattress. As this combination of materials is fed into the machine, the operators uses their skill to feed the proper amount of each material into the machine to produce a professionally tailored product.
• 6 Some of the highest quality mattresses may also feature a pillowtop, a panel filled with soft upholstery and attached to the top and bottom panels of the mattress for a more luxurious feel and appearance. Prequilted, the pillowtop is then taped to the mattress.
Boxsprings
• 7 If the desired boxspring has a spiked coil design, it is made by stapling the bottom of each coil to a flat wooden frame. A wire grid is then placed on top of the springs and, once aligned, manually locked to them. A thin layer of upholstery is applied to the top. If the desired boxspring contains no springs,
Once the cover is quilted, it is cut into top, bottom, and side panels. Next, flanges are added, and hogs rings are stapled to them. Finally, in the closing operation, workers use a movable sewing head mounted on a track to feed the top, bottom, and side panels and a heavy duty binding tape into the sewing machine as it moves around the mattress. The mattress is then ready for packaging.
it consists of a wooden frame that may or may not have a layer of upholstery attached to its top. Regardless of the internal composition, the frame is usually inserted into a pre-sewn cover that encases the top and sides of the unit. A border fabric that matches the mattress exterior is applied to the sides, and a dust cover is added to the face.
Inspection, labeling, and packing
• 8 Once the units are complete, they are inspected for quality. If every thing is in order, they are labeled with the content and the contingent “do not remove” tag, required by law to ensure the consumer that the contents are properly represented in the labeling. The finished product is then transported to the packing area. Here it is inserted by hand or by automated machinery into protective plastic or paper covers. Additional information about the warranty, safety, and care of the product is also included in the packaging.