This is where it gets interesting. Did you know that there are only two innerspring manufacturers in the United States, and one of those companies has an overwhelming market share? Leggett & Platt is a four-billion dollar a year corporation that manufactures more innersprings than any other company in the US. Sealy, Simmons, Serta, Sterns & Foster don’t own steel plants nor do they “turn” their own springs. What they do, as well as any other mattress company you can think to name, is use innersprings from Leggett & Platt. Our Factory uses the same innerspring units.
What about foams and padding? Another company you may have heard about, as they have been based in Richmond since 1957, is Carpenter Company. They are an International Company and the world’s largest manufacturer of cushioning products for the bedding and upholstery industries. Once again, all the big name mattresses use their foam and cushioning products. We use them also.
You might ask: What about memory foam like in the Tempur-Pedic beds? Just do a Google search for “Memory Foam Products” and have a few hours on your hands. Their foam is nothing special, but they don’t want you to know that. Visco-Elastic Memory Foam is available from several sources in various weights.
The bottom line is this: No matter the brand label, marketing hype, salesperson’s story, fancy store or high prices….all manufacturers use the same suppliers. Simply put no one makes a mattress, they assemble them from supplied products. And the list of suppliers is a whole lot shorter than you might imagine.
As for construction techniques, the manufacturing process is the same in every factory. They all buy the same assembly machines from the same suppliers. All they really do is customize the outer quilted fabric from brand to brand and model to model. Some have a little more of this foam and a little less of that foam so they are different and special, or so they can be marketed as such.
All this should cause you to ask yourself a question. Why should I pay more for the same materials and construction techniques just because the higher priced mattress has a label with a name I’ve seen advertised on TV? You shouldn’t, unless you feel an overwhelming obligation to help them with those advertising costs!
A warning about Foam Encased Mattresses: This is promoted as a feature that expands the sleep surface and firms the edge of a mattress. If you sit on the edge of your mattress when you wake in the morning to put on your shoes, this firm sitting edge will soften and turn into a soft sitting edge also changing the sleep surface at the edge! The real reason for foam encasement is that it saves the manufacturer lots of money. Plastic foam is much less expensive than spring steel. Foam encasing a mattress reduces the amount of spring steel used by eighteen percent. Then it gives the manufacturer a marketing ploy to promote their mattresses and to convince the customer to pay more money for the extra feature.
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