How Bed-in-a-Box Mattresses Are Produced

Over the past decade, bed-in-a-box mattresses have been taking the world by storm. With all the typical headaches involved in mattress shopping — from visiting the showroom and choosing a mattress to expensive delivery and setup costs — the idea of receiving a compressed foam mattress shipped to one’s home in an easy-to-handle box appeals to millions of consumers. From the original Bed-in-a-Box created in 2007, we now have close to 200 companies now following the same model — and demand continues to increase.

Obviously, with all these companies now contending for market share, the field has become quite competitive, and manufacturers are now under increased pressure to get their mattresses built and shipped more quickly than ever. For a business model that essentially builds mattresses on demand, this presents some unique challenges, causing some to re-think how their bed-in-a-box mattresses are produced. Many have discovered that using hot melt systems for product assembly can greatly shorten the amount of time it takes to build and ship a mattress. Let’s take a look at how these mattresses are made and how hot melt systems can reduce production time.

The Manufacturing Process

For many bed-in-a-box companies, if not most, their mattresses are made to order, and construction doesn’t begin until the customer places an order online. The reasons for this range from customization options to logistical space (many of these boutique companies don’t have room to store large amounts of inventory). Each mattress is constructed of state-of-the-art memory foam which has the ability to be highly compressed and rolled for shipping. The biggest delay in the manufacturing process is in applying the adhesives to build the mattress itself — water-based adhesives require 24 hours or more for curing. When a company has limited space, they can only cure so many mattresses at a time, which can cause even more delays in the supply chain. Before long, customers get impatient. Needless to say, a company that can overcome these delays and streamline the manufacturing process can be highly competitive.

Some companies have overcome this challenge by using hot melt adhesives in place of the standard water-based adhesives. Hot melt adhesives are just as effective and enable the same level of quality in bed-in-a-box mattresses — they just cure much more quickly. Using a hot melt system, a manufacturer can produce, compress, roll and ship a bed in a box within hours, rather than days, greatly streamlining their workflow and keeping customers happy in the process.

Sure Tack offers an array of hot melt systems that are perfect for companies looking to streamline their production. If you’re a bed-in-a-box company or another manufacturer looking to shorten your turnaround time, a hot melt adhesive system can greatly accelerate your manufacturing process without impacting quality control. To learn more about whether a hot melt system is right for you, call us today at 800-580-2803.