Behind the Scenes at Denver Mattress

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Denver Mattress is considered unique among its competitors in the bedding industry, but how does it earn its success? From its factories, managers, and workers, Denver Mattress has been titled with having one of the most efficient mattress assembly lines in the world, but there’s a lot of work that goes into making sure they’re consistent in terms of quality. Karen Goossens, the National E-Commerce Manager from Furniture Row, sat down with the Front Door to answer questions about what goes on behind the scenes at this unique company.

Front Door: How does Denver Mattress produce consistent body support and enable a restful night’s sleep with minimal interruptions?

Karen Goossens: Everybody has different comfort and support needs in a mattress. What sets Denver Mattress apart is that we truly care about helping you find the mattress that fits you best. We offer a variety of different support systems, from zoned support, which offers extra support where you need it most, to individually wrapped coil and foam support systems, which provide excellent motion separation for couples. We even carry adjustable air chamber systems for truly customizable support.

FD: What does Denver Mattress do to ensure quality over time? 

KG: Being a factory direct company, Denver Mattress takes a lot of pride in the quality of the mattresses we produce. The fact that we make the mattresses ourselves gives us control of the components that go into them and we use the highest quality materials we can for every price point; for example, all of the foams that we use are CertiPUR-US® certified to ensure quality.

Also, during design and development, Denver Mattress uses tests that simulate how the mattresses will perform through time with actual use. They are then measured and inspected for wear to ensure quality. The mattresses must perform well in testing before they will ever make it to a showroom for a customer to purchase.

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FD: How does Denver Mattress minimize waste while producing mattresses?

KG: We like to use the term up-cycle instead of recycle because we are repurposing all virgin materials. Our M.A.R.S (Materials Automated Recapture System) takes all of the excess fabric trimmings and creates a new fiber that can be used to make pillows, mattress pads, etc. We also recycle all plastics and cardboard which makes the factory a zero waste facility.

FD: Where does Denver Mattress find inspiration for new mattress technology? 

KG: I think the biggest source of inspiration is listening to our customers. We are able to see what types of mattresses they are looking for and also look for gaps in products that are available. In addition to that, Bob Rensink, who runs our factory, stays on top of all of the latest mattress technologies that are available, so he is constantly coming up with new ideas to try. 

FD: Take us behind the scenes in the factory. What kinds of manufacturing procedures do the products experience before they hit stores? 

KG: Denver Mattress utilizes J.I.T. (Just In Time) manufacturing. Because mattresses are produced on demand, little to no inventory is stored in the factory. The raw materials are assembled together into a mattress and then immediately sealed in plastic and loaded for distribution to our stores. The entire process ensures consistent quality and very efficient production.

FD: What’s one fun fact about mattresses you think people should know before making a purchase?

KG: You always hear about the fact that you spend 1/3 of your life in bed. However, think about the impact your sleep has on the other 2/3 of your life. Sleep has such a dramatic impact on your health; it ranks right up there in importance with diet and exercise.

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FD: Do you have any additional thoughts or comments?

KG: The main thought I would like for people to know is that there is no “one size fits all” when it comes to a mattress. You need to find the support that fits your body and lifestyle the best. Our complimentary custom mattress fittings will help you find the mattress and pillow combination that your body needs to put you in neutral spinal alignment. This helps your muscles relax and minimizes pressure points on your body, so you can get a better night’s rest.

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