Behind the scenes, or BTS as called by the acronymization enthusiasts, are fun. It is interesting for most of us to know the behind the scenes of any famous show-biz products. How about the thing we sleep upon every night? Have you ever thought about it? How are the mattresses made? Here we are going to look into the making of a premium micro pocket spring mattress which is the largest selling model of mattress in UAE.
Steps that Matters
I am breaking down this total process into 9 steps for your better understanding. Hope this gives you a good idea about premium bed production.
Steel for the spring
For a luxury mattress, especially for a micro pocket spring mattress, manufacturers give utmost care right from the selection of raw materials. So, right from the selection of steel coils for the spring, they should be careful. No matter that they are going to be in the core of the mattress body. Here they use high quality stainless steel coils to make the spring.
Fully automated spring construction
The stainless steel coils are fed into a fully automated spring making unit. Among every bed company in UAE, this setup is one of its kind. From there springs with equal length, expanded heights, spirals and uniform diameter are produced. The ones that cannot meet the uniformity are expelled in the process itself. Only good quality springs are forwarded to the next step.
Pocketing the springs in high quality fabric
The individual springs are fed to the chamber where they are loaded to small pockets made of high quality fabric. The fabric is also selected carefully so that it can last long. Each spring is packed in the pockets and joined together according to the width of the mattress.
Frame to arrange and hold in place
These sets of spring pockets are arranged according to the length of the mattress. This will make a bed of pocketed spring. This setup is then fitted with a pair of frames. One at the top and the other at the bottom to hold the springs in place.
Once the frames are attached, the height of the springs should be intact. For this purpose prefabricated connectors are attached to different locations at each of the four lateral edges of the bed of pocketed springs. This process is called edge reinforcement. This also helps to fix the position of spring pockets in a single line.
Spring layer outlined
After the reinforcement of edges, the bed of springs is covered with a hard sponge layer. This outlining with a hard sponge acts as a barrier between the bed of springs and the outer surface. It also keeps the bed of springs at the preferred position within the mattress body. Every spring based luxury mattress in UAE comes with this outline.
Sandwiching with Sponge Layers
The bed of spring is then sandwiched with layers of sponge. There will be at least two layers of different sponges at each side. Both top and bottom. One layer of hard sponge and another layer of memory foams are used at both sides. This is to make sure that the bed is usable from both sides.
Outer layer of quilted fabric
The outer layer is made of quilted fabric which has a sewn-through design. After the covering layer is given, edge cutting and edge sewing take place. This is done using semi automatic machines. This process needs top level accuracy as the stitches and finishing is much significant for a premium mattress in UAE.
Additional detachable layers
Height adjustable mattresses are those that can be used in various heights according to preferences. The height adjustment is made possible by the inclusion of detachable layers to the bed. These layers normally contain majorly memory foam and sponge in quilted cover. This property is not common for every luxury mattress in Dubai.