Production system


 

PRODUCTION SYSTEM

 

The company has its own manufacturing facilities, located on 40000 m2 which are equipped with the latest high-tech production lines supplied by renowned companies.

Thus, by production capacity and quality of production, the company ranks amongst the leading companies producing mattresses and sleep accessories in Egypt and Middle East.

Driven by our desire to satisfy the highest demands of consumers, we always use the best quality and ecologically pure materials in mattress production, such as natural cotton inserts, polyurethane HR foam, foam latex, viscoelastic foam "memory foam", cotton and wool padding, etc.

We use our own machinery and other industry top-of-the-line equipment to make your product last for years to come.

Modern machinery, ecological materials, and highly qualified team are the basis of the high quality products that we manufacture for healthy rest.

 

INNERSPRING SUPPORT SYSTEM

Innersprings:

Innersprings are the most common type of support system used to make mattresses. These units are comprised of metal coils that are either pocketed or open and laced. Innersprings conform to and support your body by allowing your hips and shoulders to penetrate the surface while allowing the back to be supported in its proper position.

 

1 - Coil Count:

The number of coils in the unit. Counts are usually quoted in full or queen sizes. The number of coils alone has little bearing on the quality of the unit. The coil design, wire gauge and number of turns must also be considered.

2 - Wire Gauge:

The thickness of a wire. The lower the number, the thicker and more durable the wire. For example, a 12 ¾ gauge wire is thicker than a 15 gauge wire.

3 - Number of Turns or Rotations:

A coil turn is defined as a complete rotation in the coil. More turns equates to more coil resiliency and longer coil life. In addition, more turns allow the sleeper’s weight to be distributed across more wire, resulting in less wire fatigue in the coil.

 

4 - Unit Size:

An innerspring unit can be standard size or foam encased. In the former, the coils extend from edge to edge, providing uniform support. Some standard size units also have a border rod around the perimeter for additional edge support. In a foam encased unit, which is smaller in size, coils are removed and replaced with a foam edge. All innerspring units used by Janssen Group Factories are standard size units with a border rod construction.

Border Rod

Foam Encasement

Design of the Coil:

There are five basic types of innerspring coil designs: Marshall, Bonnell, LFK, Offset and Continuous.

Marshall Coil

Marshall Coil – A straight barrel, unknotted coil that is encased in fabric.  It is sometimes made with non-tempered steel, which reduces the long term resiliency of the springs.  (Also known as a pocketed coil.)    

Tempering: Tempered innersprings are stronger, more resilient and therefore more durable.  The tempering process, which involves heating the wire or innerspring unit to a high temperature, can be done electronically or in a tempering oven.  The term “double tempered” or “twice tempered” is often used in the industry, but once a coil has been heated to the optimum temperature to achieve tempering, it cannot be tempered twice.

  

Bonnell Coil

Bonnell Coil - An hourglass shaped coil with a round, knotted head.  It is made with tempered steel and is commonly used in most national brand entry level products as well as some promotional products.  

LFK Coil

LFK Coil - A straight barrel coil with an offset, squared and unknotted head. It is made with tempered steel and is a premium innerspring unit utilized in the flagship product lines of several brands.

Knotted Coil

Offset Coil - An hourglass shaped coil with a square head that can be knotted (as shown below) or unknotted.  It is made of tempered steel and is used in premium quality innerspring units found in high end luxury brands. Our best Offset knotted coil unit is used in our Orthopedic mattresses.

Knotted Coils: The end of a coil is either knotted or unknotted. Knotting utilizes more steel and gives the coil more stability.

Continuous Coil

Continuous Coil - A strip of coils that runs either vertically or horizontally with each head representing the end and beginning of consecutive coils.  It is made of one piece of tempered wire and commonly has a high coil count, but uses less steel and a much thinner gauge of wire with a low number of turns.

 

Foam:

Foam mattresses are becoming increasingly popular in today’s market.  Like an innerspring mattress, foam conforms to and supports your body by allowing your hips and shoulders to penetrate the surface while allowing the back to be supported in its proper position. 

If you are interested in a mattress with a foam core, there are a few different kinds of foam available.  It is important to consider the type of foam as well as its density and Indentation Load Deflection (ILD).  ILD is a measure of a foam’s load bearing capacity and is indicative of the foam’s feel (hardness/softness).

Polyurethane Foam:

Polyurethane foam is a synthetic material that is produced by a reaction between two chemicals, a few minor ingredients and water.  It is then solidified into foam via one of two processes:  the Slabstock Process or the Molded Process.  In the former, a chemical mix is poured onto a moving conveyor belt, where it is allowed to react and expand.  The slab is then cut, stored and allowed to cure for 24 hours.  The Molded Process differs only in that the chemical mix is poured into specially shaped molds as opposed to an open conveyor. 

The resulting product of either process is polyurethane foam, which is made up of a network of tiny interlocking support cells consisting of “struts” and “windows”.  The “struts” form the support structure of the foam while the “windows” or voids allow it to circulate air and “breathe.”  As such, polyurethane foam is both durable and lightweight.  It conforms comfortably to an individual’s body shape and is also available in a range of densities.  A higher density of foam means that there is more “strut” material, which gives the foam an increased amount of support and durability.  Density is a measure of weight per unit of volume (i.e. lbs/ft3).

Latex Foam:

Latex literally means “polymers suspended in water” and can be 100% natural, 100% synthetic or a blend of the two.  It is manufactured via one of two processes: the Dunlop process or the Talalay process. 

Viscoelastic Foam (Memory Foam):

Viscoelastic foam is a type of polyurethane foam and is therefore synthetic.  Its name is derived from the word “visco,” which means “resistant to change of shape” and “elastic,” which means “the ability of something to return to its original shape after being forced to change.”  Viscoelastic foam, which is commonly known today as memory foam, was originally developed in the late 1960s by NASA.  The result was a very dense, open cell variety of polyurethane foam that molded to the weight and shape and temperature of an individual.  Unlike latex or standard polyurethane foam, it is a slow-response foam and gradually conforms to your body and temperature.  It also takes a certain amount of time to recover and resume its original shape.  Due to its high density, it helps to reduce pressure points as well as minimize motion transfer.  However, it is not as breathable as other mattresses and has a tendency to become hot while you sleep. 

 

 

TYPES OF MACHINES, USED AT OUR FACTORIES

QUILT MACHINES

MULTI NEEDLE QUILT MACHINES

At Janssen Group Factories, layers of quality foam and fiber are fed into multi needle quilt machines. Here, many needles work together to stitch these layers to the mattress fabric, forming a single quilted pad. 
This quilted pad is then handled in one of two ways:

·         It is spooled into large rolls holding up to 50 yards to be cut into panels at a later date.

·         It is cut into standard or special size panels to put on the top and bottom of our Twin, Full, Queen, King and custom size mattresses.

BUILDING A MATTRESS

When building a mattress, Janssen group Factories follow the steps listed below:

·         A bare mattress spring is selected based on the size and model of the mattress to be built. This unit is then placed on a table that is specially designed for making mattresses.

·         A thick layer of cotton padding is placed over the coils. Cotton is used when building a mattress to enhance the durability, comfort and tailoring of the final product. Padding materials will vary based on the type of mattress that is being made (i.e. Plush, Extra Firm or Pillow Top).

·         A layer of convoluted foam is placed on top of the cotton.

·         The 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 padded materials.

·         In building a two-sided product, the mattress is flipped and the process of layering the materials is repeated so that the padding is the same on both sides. Janssen Group Factories offer a number of two-sided products because we believe in making mattresses with your long term comfort and durability in mind.

TAPE EDGE MACHINE

The tape edge operation is considered to be one of the most difficult jobs in a bedding plant. The operator needs to use the tape edge machine to sew the top quilted mattress panel to the side border using a binder, walking backwards as he does so.

In the course of a day, the tape edge machine operator will walk about a mile backwards. After one side is done, the operator flips the mattress and does the other side. A two-sided pillow top style mattress needs to be sewn twice on each side.

SEWING MACHINE OPERATION

A skilled operator uses a sewing machine to stitch a pre-cut piece of non-skid material to a quilted border using a binder.

 

UPHOLSTERING A BOX SPRING

Janssen Group Factories follow these steps when upholstering a box spring in one of our factories:

·         A box spring with an Amish built wood-frame is selected based on the model to be upholstered. Box springs vary based on the amount of wood and wire used. The box spring unit is placed on the pre- upholstery table and corner straps are attached.

·         An insulator pad is then placed on top of the unit and wrapped on all four sides. Next, the cover is fitted over the whole unit.

·         The boxspring is then flipped over onto the box spring upholstery table and compressed about 1 inch. The cover is then attached to the frame using a pneumatic stapler.

·         A layer of non-woven material is then stretched across the box spring and secured to produce a dust barrier. The box spring upholstery is then complete.

No matter what your shape or size, we guarantee to give you a bed that's appropriate for you. We go through turns of the coil, gauge of wire, weight of the coil unit, type of edge support, amounts of fiber, types and densities of foam, and even the thread count to the cover. We carefully gauge your reaction to these components to make sure your mattress is as comfortable as possible for as long as possible, and we always guarantee the lowest price. Don't see what you need? Call us - if we don't have it - we'll MAKE IT! Whatever it Takes!

 

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