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Maplewood Custom Bedding Company is a family owned and operated business committed to delivering customer value through quality products and personalized customer services. We stand behind all our products for years of comfort and satisfaction!
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Layers of quality foam are fed into the quilting machine. Here many needles work together to stitch these layers to the mattress fabric, forming a single quilted pad. This quilted pad is then cut into twin, full, queen, king and custom size panels to put on the top and bottom of each mattress.
A bare mattress spring is selected based on the size and the firmness of the mattress to be built. A thick layer of cotton padding is placed over the coils. Cotton is used to enhance the durability, comfort and tailoring of the mattress. Padding materials will vary based on the type of mattress being made.
A quilted cover sewn on the multi-needle quilt machine is then placed on top of the padding layers and attached to the coils to prevent shifting of the padding materials.
The mattress is then flipped and the process of layering the materials is repeated so the padding is the same on both sides.
A foundation or box spring is chosen based on the model to be upholstered. Box springs vary based on firmness. The unit is placed on the pre-upholstery table and corner straps are attached.
An insulator pad is placed on top of the unit and wrapped on all four sides. Next, the cover is fitted over the whole unit.
The cover is then attached to the frame using a pneumatic stapler.
A layer of non-woven material is then stretched across the unit and secured to produce a dust barrier.
The final step is to attach the protective corner guards to the box spring unit with the pneumatic stapler.
The tape edge operation is considered to be one of the most difficult jobs in our factory. The operator needs to sew the top quilted mattress panel to the side border using a binder, walking backwards as he does so. After one side is done, the operator flips the mattress and does the other side.
The sewing machine operator takes a pre-cut piece of non-skid material and sews it to a quilted border using a binder. The spools of binding thread contain approximately 18,000 yards or 10.23 miles of thread.
Maplewood Custom Bedding Company - 3110 Sutton Avenue - Maplewood MO 63143 - (314) 645-1380