Reliable mattress manufacturing company in Cheshire
Starleda International is a UK based mattress manufacturing company that offers a wide range of services to both local and overseas customers. We cater to the European market while serving customers in the Middle East. We manufacture a range of quality mattresses in our company warehouse using memory foam. Memory foam mattresses are made using a sequence of high-tech manufacturing processes. The look of this memory mattress is just like any other mattress, but a unique feature of this is its visco-elasticity. Over the years, we have developed a range of products, using the finest raw materials and sourced finished products. We have inspected and selected them for your comfort. Our 'Sleep Comfort' product range consists of orthopaedic pillows, mattresses & mattress toppers, in addition to high-quality men's shirts and ladies shirts/blouses.
Settle down on a comfortable mattress
We can manufacture a range of memory mattresses, along with orthopaedic pillows and Visco memory toppers. Manufactured in Germany, the memory mattresses act as firm support for your back. The product surface moulds with the shape of your body for your comfort. It helps in relieving pressure points and can offer complete relaxation to your aching hips, legs, and shoulders. So settle down on your comfortable mattress for good night sleep.
How we make memory foam mattresses
The "comfort" layer (other wise known as quilt) starts with "ticking", this created using either polyester or cotton polyester, under this there are layers of polyester cloth, foam and fiber - luxury mattresses contain wool, silk or cashmere fiber. The assembled layers go through a sewing machine which stitches in the design, a roller will hold this down so the needle can pierce all the layers.
The two polyester layers inside the mattress are essential, one is directly under the "ticking", this layer acts as a barrier against scratchy fibers from poking through the top of the mattress, the other is at the bottom of the quilt, it holds the stitches in place and stops them from moving around and damaging the foam.
After this a cutting wheel will trim the mattress to the appropriate size, leaving a little extra space around the mattress, this ensure the foam reaches all the way to the edge once the quilt is sewn up. When the mattress goes to be sewn it's done on an air cushioned table, similar to that used for air hocky. This makes the quilt easier to manover as it's stitched closed. A polyester band is then attached to the perimeter of the quilt, while this is happening the mattress sides are created from the same ticking used earlier in the process. This is attached to a thin foam sheet.
Automated machines create the coils used in the mattresses, these are put into cotton sleeves to prevent them from tangling together, the spring during production the machine curls the two ends of the wire into a shape similar to that of a pigs tail, this prevents the sharp ends from poking through the mattress surface. The springs are placed in rows then fed into a machine which connects them by running long strips of curled ("pig-tailed") wire along the top and bottom of the springs. Using more wire a thick steel "edge wire" is used along the top and bottom perimeters of the mattress. Steel brackets called "edge guards" add more strength to the mattress when it's being sat on the edge. The pocket springs are glued together at the centre, this allows for independent movement, so movement on one side of the bed won't effect the other side. A sheet of "reinforcement netting" is added to hold the coils in position, these are connected through thick steel which is added to the outside of the netting.
After adding 2 layers of foam a quilt is added to the top and bottom of the mattress by stapelling the the polyester band on the quilts underside to the metal components in the mattress. The final step is to attach the sides, a specialised machine is used to join them to the quilt with a reinforcement strip made of durable fabric.