How to Make a Pocket Coil Mattress? A Comprehensive Guide for Export Markets

The pocket spring mattress has gained significant traction in international markets, including the United States, Australia, Europe, New Zealand, and South Africa, due to its superior comfort, durability, and motion isolation characteristics.

This guide provides a detailed overview of the pocket spring machine manufacturing process, focusing on key technologies and equipment that can optimize production for international mattress manufacturers.

What Is a Pocket Coil Mattress?

Pocket spring mattresses are engineered with numerous individually encased springs, each housed within a separate fabric pocket. Unlike traditional Bonnell spring systems, pocket springs operate independently, providing targeted support and pressure relief. This design is prevalent in premium bedding, a rapidly expanding segment within the global furniture market, which drives demand for high-efficiency pocket coil mattress manufacturing solutions.

Pocket Spring Mattress Production with Detailed Process

The pocket coil mattress manufacturing process involves several steps:

Step 1: Spring Coiling

High-carbon steel wire is coiled into springs using a pocket spring coiling machine. Manual production methods or older spring machines present challenges in adjusting spring height prior to pocketing, limiting the ability to produce zoned mattresses and ensuring consistent spring dimensions and elasticity.

Step 2: Pocketing the Springs

The coiled springs are inserted into non-woven fabric pockets, providing each spring with independent movement to enhance motion isolation. While various non-woven materials are available, manual pocketing is inefficient and prone to errors, such as spring puncture, leading to material wastage.

Step 3: Assembling the Pocket Springs

The pocket springs are arranged into rows and secured using hot melt glue or ultrasonic welding, forming the mattress core. Manual gluing can result in adhesive waste and inconsistencies, leading to structural defects. Ultrasonic welding, favored in markets like the United States, Europe, Australia, and Japan due to its environmental benefits, eliminates formaldehyde emissions, making it a preferred method for high-end mattress production.

Step 4: Edge Frame Application

The perimeter of the spring unit necessitates the application of edge support components. Typically, sponge material is affixed to the four lateral aspects of the spring unit, with PK cotton integrated on the upper and lower surfaces to augment edge stability. Manual sponge adhesion mandates a collaborative effort involving at least two operatives, alongside the utilization of calibration instruments to mitigate adhesive misalignment.

Step 5: Comfort Layer Integration and Quilting

Dependent upon the desired firmness profile of the finished mattress, comfort layer materials, including foam, latex, and micro-coils, are bonded to the upper and lower surfaces of the spring unit. Subsequently, a mattress tape edge sewing machine is employed to secure the mattress ticking around the perimeter.

Step 6: Compression and Packaging

Upon completion of the mattress fabrication, the product undergoes coating, compression, folding, and rolling procedures, contingent upon storage and logistical requirements. Coated packaging, utilizing film, presents a cost-effective solution with inherent dust-resistant properties, suitable for localized distribution. Conversely, kraft paper offers superior dust and moisture protection, rendering it optimal for export and e-commerce applications. Numerous mattress manufacturers opt for compression and rolling of spring mattresses, followed by carton packaging, to optimize space utilization and facilitate efficient warehousing.

Optimal Equipment Selection

Pocket spring mattresses, representing a premium product category, necessitate a meticulous manufacturing process. Consumer expectations regarding finished mattress quality are elevated, prompting manufacturers to source fully automated pocket spring production machinery and pocket spring gluing systems. Automated production methodologies ensure process uniformity and accuracy in pocket spring assembly, concurrently minimizing labor expenditures. The entire production sequence can be managed by a single operator via a touchscreen interface.

Pocket spring mattress fully automatic production line equipment list

· Pocket Spring Machines

· Pocket Spring Assembly Machines

· Mattress Roll Packing Machines & Mattress Compression Machines

· Mattress Box Sealing Machines

· Tape Edge Machines

Equipment pricing is contingent upon production velocity; therefore, a thorough evaluation of investment parameters is recommended. For recommendations on spring production machinery, including best-selling models and the latest technological advancements, we offer a proprietary technology: ultra-high spring preload technology.

This innovation facilitates the production of products with equivalent firmness characteristics at reduced operational costs. This product is showcased annually at the German Furniture Fair, Dubai Sleep Show, and China International Furniture Fair, consistently generating significant international interest. To date, we have successfully deployed thousands of units. A concise product overview is provided below.

LR-PS-UMS/UMD Mattress High Compression Pocket Spring Coil Machine

Main Feature:

√ 160 springs per minute, patented technology to produce stronger support springs at lower cost.

√ Intelligent spring adjustment system: two types of high-compression springs and ordinary springs can be produced , easy to adjust the height and diameter of the spring.

√ Equipped with a CNC system, screen touch control, visualization of production capacity, and easy to operate.

Case illustration of cost saving:

We can use a high-compression spring in 1.7mm instead of a conventional spring in 1.9mm.

If each High compression spring in 1.7mm weighs 19.73g and Conventional spring in 1.9mm weight 24.34g, the weight saved per spring: 24-19＞4g;

If the size of spring unit is 2000x1500mm, spring count is 32x23=736 springs

The wire weight saved per spring unit: 4x736=2944g≈3kg

The cost saved per spring unit: $0.93/kg x 3 kg = $2.79

Total savings per day: $2.79 x 500 = $1395

FAQ

Q1: What distinguishes a pocket coil mattress from a conventional spring mattress?

Pocket coil mattresses incorporate independently encased springs, facilitating superior support and motion isolation relative to the interconnected springs found in traditional designs. This characteristic renders them particularly well-suited for premium bedding applications and export markets.

Q2: What machinery is requisite for initiating pocket coil mattress production?

At a minimum, the procurement of a pocket spring coiling machine for spring fabrication and a pocket spring machine or an automated pocket spring assembly system for fabric insertion and unit assembly is essential. Additional machinery for gluing, compression, and packaging can further augment operational efficiency.

Q3: Is automated machinery appropriate for small-scale mattress manufacturing facilities?

Affirmative. While large-scale manufacturers may opt for comprehensive pocket coil mattress production lines, compact and economically viable machinery solutions are available for startups and small-batch production scenarios.

Q4: What is the typical production cycle time for a single pocket coil unit?

With contemporary equipment, production cycle times can be as swift as 30–60 seconds per unit, leveraging high-speed pocket spring machines—significantly enhancing daily output compared to manual assembly methods.

Q5: Are pocket coil mattresses amenable to compression and boxing for shipping purposes?

Indeed. The majority of units produced via current pocket coil mattress manufacturing processes are engineered for compression and roll-packing. This is of paramount importance for mattress machinery intended for export markets and e-commerce fulfillment.

Conclusion

Understanding how to make a pocket coil mattress is not only essential for producing quality products but also for building a globally competitive manufacturing operation. From the pocket spring coiling machine to automated assembly and packaging systems, investing in the right technology is the foundation of success.

Whether you're upgrading your production line or entering new export markets, now is the time to invest in smart, scalable, and efficient pocket coil mattress manufacturing solutions.