Mattresses for sofas, sofas, armchairs. How modern mattresses are made

Mattress production: step by step technological process + necessary equipment for the production of mattresses + detailed nuances business.

It is very important for every person to get enough sleep. To maintain health and recovery nervous system you need to sleep 7-8 hours a day. At the same time, nothing should disturb sleep. And the quality of rest, in turn, largely depends on the quality of the bed.

The only right place to sleep is a bed with an orthopedic mattress. Sofas are absolutely not suitable for sleeping at night. And not only the sleep itself, but also the health of the spine and back as a whole depends on the quality of the mattress.

Today, the mattress market is actively expanding. People buy them for both adults and children. Therefore, the profitability of such a business is completely justified. And if an entrepreneur plans to develop the production of mattresses, it is necessary to study the production technology and equipment that will be required for this.

How to open your own “mattress” business?

At first glance, it seems that it is enough to buy the necessary equipment, and the production of mattresses will be ready to start. In fact, certain technological knowledge and a package of business registration documents are required.

So, a businessman needs to officially. In this case, experts advise registering an LLC, which will provide much more opportunities for production. After all, large investors work only with legal entities, which is what LLC is.

The following package of documents is required for registration:

1. Charter of the meeting of founders.
2. The decision of the meeting to open an LLC.
3. Application for registration.
4. A receipt indicating payment of the state duty.
5. Copy and original passport of the LLC director, accountant.

You will find detailed information on the Federal Tax Service website: https://www.nalog.ru/rn77/yul/interest/reg_yl/register/

To start production, you also need permission from the sanitary and epidemiological inspection.

You will also have to decide where to purchase or rent a suitable building. The production of these products requires a premises of at least 125 sq.m. The cost of such a territory is about 50 thousand rubles. per month.

note: this area does not include warehouses, office area.

3 main stages for mattress production

In the last century, mattresses were made by hand. Basically, these were thin layers of cotton or foam rubber, covered with simple fabric. Today there is a certain technological process for the production of mattresses.

It is impossible to make a modern mattress without the use of special equipment. Yes, today there are still manufacturers who make products by hand. But, as a rule, these are large, branded companies. These belong to the “Premium” class and are made to order.

The entire technology for producing feather beds is divided into three stages.

No. 1. Production of mattress bases.

In most mattresses, the main element is a spring block. It is made of steel in combination with a carbon compound. The latter gives the structure strength and durability.

Mattresses low pricing policy are produced on the basis of a combination of simple springs with each other. In orthopedic structures, they are assembled into separate blocks and located around the entire perimeter in a specific sequence. This allows you to avoid the appearance of dents and pressing through of springs over time.

If each of the springs is independent, separate, the load on the feather bed is given only when the body is positioned vertically. Thanks to its spring independence, the mattress precisely takes the shape of the human body, which protects the back from curvature.

After producing the base and frame, the filler is selected. It is based on the springs and filler that the cost is calculated finished product.

Among the most common fillers are the following materials:

• latex polyurethane foam;
• latex;
• mammal hair;
• coconut coir;
• memorix;
• felt;
• struttofiber.

No. 2. Making the mattress itself.

The production of the mattress is carried out according to a special model, which is prepared in advance.

So, parts of the feather bed of the desired shape, length and width are cut from the blanks using technical scissors. The fabric for the product is selected to be as durable as possible and can withstand varying degrees of load.

Depending on the price, the following fabrics are chosen:

1. Low price: polyester, polypropylene.
2. Average price: raw cotton.
3. High price: bamboo fibers, addition of seaweed.

No. 3. The final stage.

After production of the finished product, it is coated by special means. As a rule, these are moisture-repellent, fire-resistant coatings. Fireproof is an innovation, and this moment find on Russian market This type of flooring is not easy to sleep on.

Making orthopedic mattresses - how does it happen?

The most common and popular view mattresses are now orthopedic. Such feather beds most often use fillers that have hypoallergenic properties. Orthopedic properties are determined precisely by the base of the product.

Let's consider this parameter in more detail.

1) Dependent spring block.

The dependent spring block is a structure of double-cone springs fastened together metal frame. These springs are shaped like an hourglass.

This basis is actively used, although it is considered an outdated option. This is because the production of a dependent block is not complicated or expensive.

It is difficult to achieve good orthopedics, because when one spring is compressed, the entire block sag. These mattresses are designed for light weight people.

This type of block is not suitable for children who like to jump on the bed - the mattress will quickly sag.

2) Independent spring block.

This design is more expensive and problematic to manufacture, but is more in demand than a monoblock.

The springs are cylindrical in shape and separated from each other by an individual cover. One block includes several springs. The finished blocks are not connected to each other.

This system allows you to obtain an orthopedic mattress with uniform load distribution. The product fully accepts all the curves of the body and is distinguished by its longevity.

Also, by separating the blocks, squeaking can be avoided when putting stress on the mattress.

3) Multipocket.

Among modern options Multi-pocket frames are also used in the production of products. It consists of independent spring blocks small size– the diameter of one does not exceed 3-4 cm.

Thus, the design clearly takes the shape of the body, both horizontally and vertically. Otherwise, the “mulpocket” principle is similar to how blocks of independent springs are arranged.

What equipment is required for the production of mattresses and how much does it cost?

Before, you need to purchase or rent equipment for the production of mattresses.

Conventional production requires the presence of:

Name	Photo	Price, rub.)
Total:		3,621,000 rubles
Sewing machine		From 75 000
Overlock		From 50 000
Machine for making covers		From 500,000
Block and spring production machine		From 2,000,000
Spring Block Bonding Machine		From 700,000
Molding press		From 1,000,000
Edging machine		From 300,000

In total, to fully launch the production of mattresses, you will need to invest in the purchase of equipment from 3,630,000 rubles.

To begin with, it is better to purchase equipment that has already been used. For example, a machine for fastening used spring blocks will cost 150-250 thousand rubles. And an overlocker costs no more than 200 thousand rubles. A new imported one has a price of 5-17 thousand euros.

How much should you invest in this business?

To open a workshop for the production of mattresses, you need starting capital of 3.5 million rubles. And this only happens if all the equipment is used.

Equipment is the largest expense item. So, at least 2.5 million rubles will be spent on its acquisition. The rest is for the purchase of raw materials and rental of premises.

Profitability and payback of the “mattress” business.

As a rule, customers are reluctant to start. Therefore on initial stage The sales enterprise will engage in retail trade.

So, mattresses are low price category are estimated at 4-8 thousand rubles. a piece. A product based on an independent spring unit is priced an order of magnitude higher - 15-20 thousand rubles. Premium class products can be sold for 50 thousand rubles. a piece.

On average, the profitability of such a business is 30%. In case of stable sales, production will pay for itself in 2-3 years.

Mattress production process.

How are spring mattresses made in China?
Demonstration finished products from Chinese manufacturers.

Sales of products

In order for a business to immediately begin to make a profit, you need to research the market in advance.

Previously, mattresses were found only in specialized stores. Today, even in hypermarkets you can find departments dedicated to them. This option is the most acceptable and profitable for selling your product. But at the same time, selling mattresses to specialized stores will make it possible to sell products in large quantities.

To attract more customers, you can produce custom-made feather beds, sew covers, and mattress covers. These additional products are also popular.

As you can see, the production of mattresses can be very profitable, although it requires considerable capital investment.

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If among the assortment of our factory you could not find a mattress that suits you in size, shape or filling materials, LONAX is ready to make it for you according to individual order. From us you can order an exclusive model of a mattress with any characteristics, be it non-standard dimensions of the product, its shape, filling materials and type of cover. The conditions for manufacturing a mattress to order in Moscow can be found by clicking on one of the links below:

Mattresses of non-standard sizes

Our factory will be happy to produce any model of mattress to order according to custom sizes specified by you. You will only need to provide the required dimensions of the product (width x length), rounded to the nearest whole number (for example, 204.5 is rounded to either 204 or 205). In this case, the cost of a non-standard size mattress will be equal to the cost of the product of the next larger standard size.

For example, the necessary sleeping area has a size of 165x200. The closest to the given one will be the larger one standard size- 170x200. Accordingly, the cost of a 165x200 mattress will be equal to the cost of a 170x200 mattress.

If the length of the product increases beyond 200 cm, its price will be determined as follows:

From 201 to 210 cm +5% of the cost;

From 211 to 220 cm +10% of the cost;

Over 220 cm - determined individually.

Non-standard shaped mattress

The LONAKS factory, in addition to producing traditionally shaped mattresses, also produces mattresses for round beds. At the same time, we are also ready to fulfill orders for the production of mattresses of non-standard shapes.

The price and timing of the order are determined individually in each specific case and depend on the complexity geometric shape and product volume. IMPORTANT: the order is sent to production only after prepayment has been made.

Filling materials - choose yourself!

In assortment trademark LONAX over 70 various models. However, we will gladly accept your order for the manufacture of a mattress of an exclusive design, invented by you, based on the filling materials that you choose. Using the “Mattress Designer” service is very simple: you have at your disposal the entire variety of fillers and types of spring blocks used in our factory’s assortment, just include the necessary layers in your order, indicating required thickness each of them!

The price and timing of the order are also determined individually and depend on the type, number of layers and thickness of fillers.

Additional mattress cover option

By default, all mattresses are made with a non-removable cover made of cotton jacquard, except for children's mattresses and mattress covers, the covers of which are always removable. At your request, we can make changes to the type of fabric or additional structural elements cover.

Replacing standard cover fabric

Production times for non-standard mattresses

The standard production time for a custom size product at the Lonax factory is from 2 to 5 working days from the date of prepayment.

The Perrino trademark is of Russian origin and was registered in 2005. At first, this company was a small workshop for the production of mattresses and sleep accessories. But over the past 10 years or so, thanks to the use of our own patented technological solutions, proper management of the production process and thoughtful marketing activities, the company increased its turnover by more than 20 times. Today it is one of the leaders among manufacturers of sleeping accessories on the Russian market.

Production capacity and achievements of the company

The main production center of the enterprise is located in the city of Korolev. To increase product sales volumes, the company recently opened its own sales department in Mytishchi, Moscow region. The production of mattresses is carried out in a modern technological equipment from components that come directly from European manufacturers. Some materials were developed specifically for Perrino, so the company's products are unique on the domestic market.

Since 2006, the company has officially been a supplier of mattresses and other sleeping equipment to luxury hotels and hotels of famous global chains. Since 2015, Perrino has been constantly participating in domestic and international specialized exhibitions. The company's products have been repeatedly awarded with certificates and prizes for high quality and unique performance characteristics.

Features of Perrineau products

The Perrino brand assortment includes products in the following categories:

1. Spring mattresses with independent (separate) spring blocks. The presence of many springs per bed (from 512 to 2000 depending on the product model) makes it possible to evenly and accurately distribute the load from the body of a lying person over the surface. At the same time, the spine is maintained in the correct position, and the muscles are in a calm and relaxed state.

2. Mattresses with natural latex. The material is used in the manufacture of products as a filler. It is a frozen foamed sap extracted from a rubber tree. Retains elasticity and firmness for 10-15 years, and is characterized by high vapor permeability.

3. Memory mattresses. This material has “memory”, that is, it is able to independently adapt to the contours of the body of the person who is resting on it. It remembers the given shape and does not respond, has high strength and does not cause an allergic reaction.

4. Polyurethane foam. Inexpensive filling for mattresses, which is a foamed plastic mass. It differs from ordinary foam rubber in the type of raw materials used. Completely non-toxic, does not get wet and can withstand significant loads for a long time.

Different series of mattresses are made from the listed materials. A representative of the manufacturer or distributor will help you choose the model that is suitable for you. In this case, all your wishes, anatomical parameters and financial capabilities will be taken into account.

The Moscow region factory of orthopedic mattresses, operating since 2012, produces high-quality springless and spring mattresses in a wide range of sizes, models and filling. The low cost of mattresses in relation to their quality makes purchasing products from this factory very worthwhile.

The history of this manufacturer dates back to 2005 from the Laguna factory. In 2012, the Virtuoso Sleep mattress brand appeared. Industrial premises factories are located in Moscow, which allows us to fulfill any orders in short time. A large assortment good and not too expensive orthopedic mattresses for adults, as well as an excellent line of children's mattresses.

Violite mattresses have been produced since 2005 in the Moscow region. All products are certified and made from environmentally friendly materials. pure materials on imported equipment. The assortment includes more than 60 models of different price categories.

Beautyson is an environmentally friendly mattress manufacturer. All products are manufactured according to unique technology assembly without the use of glue. The technology has many advantages over adhesive: it manual assembly, high strength products and lack of odor. All mattresses are made from high quality modern materials, at each stage of assembly there is strict control.

Promtex-Orient mattresses have been produced for more than 10 years. The factory is proud that the best components from Belgium, Germany, Sweden, Italy, Turkey and Poland are used in production. All products have certificates and undergo strict quality selection.

The Comfort Line factory offers a wide range of mattresses, and each customer can quickly order non-standard products. Mattresses are produced on high-tech machines from European materials. The advantage is convenient fast evening delivery and a high guarantee.

Benartti mattresses are made from modern environmentally friendly materials. Production is located in the Moscow region. Much attention is paid to improving the quality of products. All products have international certificates of conformity.

The DreamLine factory began operations in 2006. This manufacturer has the widest range of mattresses from economy class to luxury models. The advantage of DreamLine is Fast shipping, good quality, production of non-standard products and a developed logistics network.

The sizes of mattresses vary. Measured in cm. The most popular:

Children's: 60x120 and 70x140.

Single: widths 80 and 90, lengths 190 and 200.

One and a half: width 120, lengths 190 and 200.

Double: widths 140, 160 and 180, lengths 190 and 200.

There are mattresses with and without springs. The main difference between them is design features. There is no clear answer to the question of which mattress of these two varieties is better to choose - this is a purely individual choice.

Model of a mattress, the basis of which is the material. Orthopedic properties are achieved due to the quality of the filler.
The best: natural latex, coconut coir, memory foam;
Price quality: artificial latex, coconut, struttofiber, hallcon;
The simplest ones: holofiber, polyurethane foam.

Orthopedic spring block.
Standard: 500 springs per bed. No “hammock” effect, no rolling down when there is a large difference in the weight of partners, noiselessness.

Possesses everyone positive qualities simple independent springs. Mattresses with such a block are considered the most orthopedic due to the increase in springs to 1000 springs per bed.
A nuance when choosing:

It has all the positive qualities of simple independent springs. Mattresses with such a block are considered the most orthopedic due to the increase in springs to 2000 springs per bed.
A nuance when choosing: For people with low weight, mattresses may seem too hard and elastic.

The most budgetary spring block and, accordingly, less orthopedic. Mattresses with this spring block can withstand from 80 to 120 kg per bed.
At additional reinforcement the springs can support up to 160 kg.

This is what manufacturers can call a thin mattress before 10 cm. Used to correct uneven surfaces of a sofa/bed/mattress or to correct the rigidity of a sleeping place.

On our website, the hardness is set based on manufacturers' recommendations, our experience and various combinations of fillers. If you are in doubt about the right choice, it is better to take mattresses with different hardnesses on the sides so that you can choose the one you like best at home.

Main price criteria are: size, fillings, type of mattress.

The characteristics of the mattresses state maximum recommended load per berth i.e. maximum weight of one sleeper.

Height does not affect on the quality or service life of the mattress. This parameter is set if there are restrictions related to the characteristics of the bed.

On our website this parameter means various contents on each side of the mattress and, accordingly, different hardness on each side.

The mattress is supplied rolled up in vacuum packaging. After opening the package, the mattress takes its shape within a few hours. If the height of the mattress is more than 10 cm, the mattress will be rolled up impossible.

Products up to 10 cm, which can be rolled or folded throughout the entire period of use. They do not contain coconut coir, struttofiber and holofiber because... These materials must not be twisted or bent.

The service life of a mattress largely depends on the materials used in its manufacture. Some turn out to be more durable and expensive, others will last less, but are much cheaper.

More dense foam. Practical, budget-friendly, easy to transport.

Artificial material fibrous structure horizontal arrangement. Most often used in mattresses for children, because withstands light loads and is a hypoallergenic material with good air exchange.

Made from holofiber. It has improved elasticity and density, so it can withstand heavy loads and can be used by adults.

An artificial material with fibers arranged diagonally. Due to of this property This material has a springy effect.

A mixture of struttofiber and coconut coir. Hard material. A little cheaper than natural coconut.

This material is polyurethane foam of an improved formula. More elastic, anatomical and can withstand heavy loads and, accordingly, is more durable than simple polyurethane foam.

Polyurethane foam with special impregnation, thanks to which the material becomes envelopingly soft and remembers the shape of the sleeper’s body. Recovers quickly when there is no load.

Hard natural material. There are no analogues in properties. Withstands heavy loads and is well ventilated. This material cannot be bent or twisted.

Essential unique breathable elastic durable soft material. Due to the increase in height it can be of medium hardness.

These parameters are set by site managers, combining mattresses into certain groups.

All mattresses that are declared by manufacturers as mattresses for children from 0 to 12 years are marked.
Spring mattresses have a low load-bearing capacity; springless mattresses contain coconut for children under 3 years of age or other materials for children over 3 years of age.

All mattresses with a load-bearing capacity of 110 kg per bed are marked.

All products in the mattress industry are environmentally friendly because... This is a hygiene product for personal use. Mattresses with only natural fillings are considered the best and the most environmentally friendly, so they are in a separate group.

Any manufacturer has a series of “Premium” mattresses. For such mattresses, special technologies, spring blocks, covers, and innovative fillers can be used in the production.

We have selected the most silent, durable and versatile mattresses.