Materials Used in Mattress Manufacturing: A Sourcing Guide

At the bottom sits the spring unit, and it is the part that does the load-bearing. In a pocket spring each coil stands in its own fabric pocket and works independently of its neighbours, so load is taken at the points where the surface is pressed rather than across a single plane. The unit's height and wire gauge are the starting point for the mattress's overall height and firmness grade.

The order above is a list of functions, not a recipe. A manufacturer who knows why each layer is there can rebuild the same function with a different thickness or grade of the material at hand. The way to decide what may replace what is to ask what job that layer was doing.

An example: thinning the support layer saves overall height but puts the same load on less material. If the thickness comes down, the density grade has to go up — dropping both variables together is how a layer stops doing its job. The logic runs the other way too: with a higher-density sheet, a thinner section may be enough.

The most tempting layer to remove is also the riskiest: felt is thin, cheap and invisible in the finished product. But when it goes, neither of its two jobs transfers anywhere else — roll foam is not thick enough to separate the coils, and the rebond sheet simply takes the coil imprint itself. Before adding or removing a layer, work out which job would be left unassigned.

YAYLA is a component supplier; it does not manufacture finished mattresses. There are four items in the range, and two of them are produced in-house while two are sourced and supplied. Rebonded foam and pocket springs are manufactured; felt and roll foam are sourced.

The distinction matters to a buyer because the conversation differs. On the manufactured items, parameters such as density grade, dimensions, coil count and height are set per order. On the sourced items, the choice is made among the thickness and width options that exist; the material arrives as an already-fixed specification.

Bringing the layers together, quilting and sewing stay on the mattress maker's own line. Items such as cover fabric, zips and edge tape fall outside this range; the four components are delivered separately, each in its own form — foam as sheet or roll, felt as roll or sheet, pocket springs roll-packed or on pallets.

A price asked for as "a mattress set" cannot be compared, because two suppliers will not read that phrase the same way. A comparable quotation is written component by component: for each item the size, the grade, the thickness, the form and the packing are stated separately.

For rebonded foam: the density grade (DNS), the sheet dimensions and thickness, whether block or sheet is wanted, and whether it is packed as sheets or as a roll. For pocket springs: the coil count, the unit dimensions, the spring height, and whether delivery is roll-packed or on pallets. For felt: the thickness, the width, roll or sheet, and standard felt or Termowat. For roll foam: the thickness, the roll width, whether it is counted by the metre or by the roll, and whether it is vacuum-packed.

Most of these parameters sit inside a range — pocket springs are worked between 500 and 1200 coils, rebonded foam in the DNS 50 and DNS 60 grades — and where inside that range you land changes what the quotation actually buys. Comparison therefore has to be between two quotations at the same size and the same grade; setting two prices from different grades side by side is not a comparison.