Our mattresses are handmade. Really.
A toy zipping down a conveyor belt, made from wooden pieces cut by a pre-programmed robotic machine then painted by an automated sprayer but in the end assembled with four bolts by hand is not “handmade” in my mind. To me, handmade is something lovingly made by a real person or persons.
Our manufacturing plant in Ohio (fully certified to the stringent Global Organic Textile Standard (GOTS), by the way) doesn’t use an assembly line, for starters. Instead, you’ll see stations where skilled craftspeople are sewing, cutting, and otherwise building mattresses, each person paying close attention to the job at hand. The process reminds me of watching an heirloom guitar being hand built.
One of the greatest features of this approach is every individual employee in our factory is empowered to stop the process if something isn’t right, and by right, I mean perfect. One of our greatest sources of pride is the pride our employees put into their craft. Of course we use machines and tools, particularly for stitching, but behind every machine or tool is a detail-oriented person obsessively checking for quality.
My favorite part, and one of the most remarkable processes to watch, is the creation of metal coils, each individually wrapped in organic cotton fabric. Amazing. To do this, we use reconditioned vintage machines from Europe that are in themselves things of beauty. The machinery creates the coiled springs from straight wire, compresses the coil and allows them to be sewn into the cotton pockets. The precision machinery, while old, is exceptionally complicated, with a remarkable number of moving parts. After each coil is wrapped, a craftsman hand attaches the individual coils.
The bottom line is we simply don’t take short cuts. We craft mattresses with real people, skillfully working together to make awesome products. That’s what I call handmade.
To watch some of the handmade process and to catch a glimpse of the machinery I mentioned above that coils the wires, check out our award-winning video.