Mattress manufacturers have many fiber choices

Get your fiber! A roundup of technologically advanced and historically proven fibers for today’s mattresses

Jones Fiber Products FR barrier

Above standard Jones Fiber Products has a comprehensive catalog of FR barrier systems that are cost-effective and durable, and perform above and beyond industry standards.

Whether you’re looking for the practical or the luxurious, there is more variety in mattress fibers today than ever before. These fibers can help regulate temperature, provide comfort, contribute to the longevity of the mattress or protect from fire. They run the gamut from technologically advanced to historically proven—and sometimes, a bit of both. And as mattresses become more and more specialized, so, too, do the fibers that go into making them. Manufacturers have a plethora of choices these days, whether they’re looking for state-of-the-art FR solutions, durable insulator pads, exotic animal hair, traditional synthetics, plant-based solutions or cost-effective recycled options.

Fire-resistant fibers

In business for more than 78 years, family-run Jones Fiber Products has produced nonwoven, fire-resistant products since the inception of 16 CFR Part 1632, the federal cigarette standard. Improvements in today’s technology have led Jones to develop some new, very lightweight, nontopically treated, fire-resistant barrier products for mattress producers challenged by 16 CFR Part 1633, the federal open-flame standard, says President Kenny Oliver.

“Jones’ approach is simple: Listen intently to our customer’s needs, engineer solutions, spend thousands of man-hours with over 2,500 qualifying lab test burns, produce consistent and reliable products, and deliver flawless service,” Oliver says. “Then repeat as the market needs change. Listening always comes first.”

Oliver says this process has created a comprehensive catalog of FR barrier systems that are cost-effective and durable, and perform above and beyond industry standards. The company uses new and innovative fiber compositions to create proprietary blends and barrier constructions, and Oliver says the company is “leading the way to better, eco-friendly, consumer-safe nonwoven products for FR barrier systems, topper pads and insulators.”

Alessandra Yarns FR barrier

Protective Alessandra Yarns uses a unique, multilayered fiber for FR barriers that are primarily used as socks or sleeves for specialty bedding.

To address the fire characteristics of increasingly popular imported fabrics, many with a high percentage of polypropylene fiber, William T. Burnett & Co. launched WhisperShield A Plus last year. The new barrier features three FR components inside: inherent modified rayon fibers, a strengthening and cooling agent.

“It works like a fire barrier on steroids—it over-performs,” says Tim McRee, vice president of William T. Burnett. “This enables bedding manufacturers to use some of these more flammable fabrics in the market today. This new product has also allowed many manufacturers to reduce the basis weight of their existing FR barrier and cut costs, some by as much as 25 to 33%.”

Alessandra Yarns uses a unique, multilayered fiber. It has a micro-denier silica fiber center, surrounded by a sheath of multifilament nylon, which is then surrounded by a sheath of various fibers, making it ideal for FR fabric development. When exposed to flame, the yarn’s filament core creates a strong skeletal framework that holds char in place, blocking flames from penetrating underlying materials.

“Everybody is always looking for a new, more economical solution,” says Karsten Siewert, sales manager. “Our objective is to research, develop and market FR yarns that will reduce fire barrier fabric costs for textile and mattress producers.”

Alessandra Yarns are predominantly used on socks or sleeves for specialty bedding, Siewert says. “With specialty bedding, it’s all about the feel and support that memory foam gives, so you don’t use a nonwoven,” he explains.

Siewert says manufacturers also use Alessandra Yarns to knit on the back of a double jersey and make a zippered cover.

Precision Custom Coatings makes FR barriers for quilt panels and border panels, including high-loft versions, needle-punched barriers and lamination—a growing trend, according to National Sales Manager Gerry Welkley.

Agru America G Series

High and low Agru America makes FR barrier fibers in high and low loft, FR filler cloth and FR prints, including the G Series high loft, shown.

“Smooth laminated borders is really a growing category in the past few years and continues to grow for us and the bedding industry,” he says. “It’s more of a fashion and high-end look, complementing the other parts of the bed, and has been well-received in the market.”

Welkley says another new technology launching next year at PCC is the incorporation of phase-change material in the FR barrier.

“Sleeping cool is such a hot topic right now,” he explains, adding that Slumber Cool has done very well in PCC’s mattress protector and encasement line.   

PCC also has developed an enhanced lighter-weight barrier over the past year that provides the bedding manufacturer a robust barrier at a more economical cost, Welkley says.

Springs Creative Products Group launched Verge, a new FR border solution for mattresses, earlier this year. Verge features patent-pending, proprietary FR technology and an all-in-one solution that avoids quilting or laminating and can be sold in pre-cut border widths.

“We think Verge is a real game-changer in terms of design and performance value,” says Jimmy Fleming, a technical sales representative.

Launched at ISPA EXPO in March, Verge has been well-received, says Scott Frisch, president of Springs Creative. Springs currently is working on some new designs for the product, including using yarn insertion rather than transfer printing, which allows for more heathered looks.

Agru America makes FR barrier fibers in high and low loft, FR filler cloth and FR prints. Brittany Garner, sales and technical manager for textile and fiber, says the company recently expanded its weight offerings down in FR fabric to 0.45 ounce per square foot and up to 1 ounce per square foot.

Springs Creative Verge FR technology for mattresses

All-in-one Springs Creative’s Verge features proprietary new FR technology and an all-in-one solution that avoids quilting or laminating, and can be sold in pre-cut border widths.

“There’s an increased desire for low weight, which offers cost savings,” Garner says. “As other material costs go up, there’s a desire for lower weight.” Garner says a 0.45-ounce per square foot fabric offers a 10 to 15% cost savings.

Agru also can make custom weights, Garner says. “We have our own burn labs, so we can run in-house tests for new prototypes, whether it’s a new ticking or new FR barrier.”

And Garner says Agru expects to launch some laminated products in 2015. “We’re moving with market trends to offer as many of those FR solutions as possible in a one-stop shop,” she says.

Renewable mattress fibers

When it comes to renewable choices, mattress manufacturers have a wealth of options. Many age-old materials and techniques are making a comeback, with fibers such as horsehair and cashmere resonating with today’s eco-conscious and luxury consumers alike. Manufacturers of “green” mattresses will find plenty of choices in plant and animal materials, from familiar cotton to exotic camel hair.

William T. Burnett recently introduced three types of wool to its fiber offerings: a high-quality New Zealand wool, a John Marshall Joma wool, and a John Marshall Merino wool.

“We’re seeing this in higher price-point bedding,” Tim McRee says. “Manufacturers are using this as a reason to justify prices in excess of $1,500 or $2,000.”

One reason for this is the way wool performs. Wool absorbs up to 30% of its weight in moisture, McRee says, and sleeps warmer in the winter and cooler in the summer. Wool made from Merino sheep is among the finest available, he says, with a micro-denier, so it’s very soft. Both types are crimped for resilience.

“It’s proving to be a great addition for manufacturers wanting to get into upper-end products,” McRee says. “There are more and more calls now for natural, compostable and renewable products at that price point; there’s more awareness of natural products. Consumers are more informed and more aware of what they’re going to be getting.”

McRee says his company is running four times the amount of wool today as it did 24 months ago, and that number continues to go up. “Every month is better than the month before,” he says. “It speaks to the awareness of the consumer.”

The Lenzing Group, maker of Tencel and other fibers, has launched a new marketing campaign focusing on combining Tencel with cotton. Rolled out in January at the textile show Heimtextil in Frankfurt, Germany, it includes the tagline “Tencel & cotton: a natural connection.” The campaign promotes Tencel as especially suited to mattresses, ticking and bed linens because of its moisture-management and “skin-sensory” properties.

Susanne Jary, head of Lenzing’s Home & Interiors business segment, says that cotton and Tencel are ideal partners for bed linens. “Even a blend with 30% Tencel gives cotton bed linens a new definition,” she says. “The touch, moisture management and sheen can be positively influenced by this combination.”

Joma wool

Counting sheep The John Marshall Joma wool has a crimp added to it for resilience and the reduction of body impressions.

Jary says the push toward blends with cotton can increase the Tencel share in bed linens. “The potential for innovation for cotton-Tencel fabrics is high and, depending on the blending ratio, properties can be changed as desired,” she says. And Nina Nadash, Home & Interiors marketing manager for North America, says she has seen “great interest” at retail in the U.S. in both the fibers and the companies using them in products.

American companies like Logan, Utah-based Malouf are making use of Tencel in bedding products,

including its new Five 5ided Mattress Protector with Tencel + Omniphase, as well as the Gel Convolution pillow, which features a 100% Tencel cover designed to wick away moisture and help regulate temperature.

For more exotic products, Volendam, Netherlands-based fiber supplier Enkev Group specializes in materials like horsehair, wool, cashmere, silk and alpaca.

“There’s more and more of a push for more natural products,” says Matt Dwyer, U.S. sales director. “Some of our traditional products are being reinvigorated into many new ranges.”

Dwyer says many top-end manufacturers are familiar with materials such as horsehair, but there is a trend for their use in a much wider market, including more volume-based, middle-range suppliers.

Enkev Fibers line of renewable fibers for mattresses

Feel natural Enkev specializes in renewable fibers such as coir, wool, cotton, sisal, jute, corn and latex.

“People are looking for something more bespoke, more high-end but at a budget,” and consumers are learning more about the comfort and breathability of natural products. At the same time, he says, “organic is becoming more important.”

“There has perhaps been surprise in how simply these materials can be incorporated into normal production methods,” Dwyer says. “We’re firmly committed to providing the levels of support to our partners in the U.S. market which has assisted our growth in Europe. We’ve seen a solid interest base grow, and further development is seen as a major focus in the coming months and years.”

Enkev is looking at distributors in the U.S. to speed up logistics and working with manufacturers to develop new products and help them understand how they can use natural materials.

“We’re trying to offer a wide range of fibers,” Dwyer says. “We really concentrate on comfort, performance and breathability, and adding value to the businesses of our customers and partners.”

Enkev boasts several trademarked products, including Cocolok, made from coconut fibers sprayed with hypoallergenic latex, and Hairlok, made from animal hair and latex.

Alpaca wool is hypoallergenic and “incredibly comfortable because of the structure of the fiber,” Dwyer says. Traditionally horsehair has been used in mattresses, and its benefits are becoming increasingly important to the consumer. “It’s pretty easy to use,” he says. “You don’t have to change anything and reinvent the wheel to use these products, but real issues and concerns in the industry such as breathability, temperature regulation and moisture control can be resolved.”

Slovenj Gradec, Slovenia-based Ko-Si also specializes in natural fibers. “Our main goal is to make more ecological materials,” says Branko Jurjec, who works in sales for Ko-Si. “It is influencing the purchasing of raw materials, the technology used and the final products.”

Lenzing Tencel

Natural connection The Lenzing Group launched a new marketing campaign this year that focuses on combining Tencel with cotton.

Coir, sisal or sea grass fiber give support to the core of the mattress. Soft fibers, such as wool, horsehair, cashmere or camel hair, provide comfort layers.

Plant fibers offered by Ko-Si include coir, which provides ventilation; sisal, which boasts a high tear resistance; sea grass, which has aromatherapy properties and provides a spring effect; jute, which is strong, biodegradable and soft; and abaca, also known as Manila hemp, which aids in temperature regulation. All products are Oeko-Tex Standard 100-certified.

Animal hair options include horsehair, which adds spring and absorbs humidity; cashmere, which Jurjec describes as “the optimal sleeping-climate regulator”; camel hair, which acts as an insulator and protects from heat and cold (much as it does on a camel in extreme desert temperatures); and a combination of wool and horsehair. 

Recycled material for mattresses

At Leigh Fibers, mattress fiber is both produced and recycled. The company reprocesses post-industrial fiber, both synthetic and renewable, for use in bedding, most often in mattress batting and insulator pads.

“We take waste from the textile industry,” explains Mark Lehner, director of procurement for Leigh. “Spinning mills buy raw cotton every season, and they create card waste and thread waste. We clean it up ourselves, and run it back through the same kind of machine—a ginning machine or lint cleaner. That industry has been around for a long while.”

Leigh also recycles materials from mattresses into automotive acoustic insulation, punching bags, targets and carpet underlay.

Lehner says this is a growing area for the company. Ten years ago, he had only three mattress disassemblers to work with; today, he has about 10.

Ko-Si horsehair fiber for mattresses

Comfort layers Ko-Si specializes in natural fibers, such as this wool and horsehair combination.

“Recycling is the opportunity of the next decade in the mattress industry,” he says.

But finding use for the post-consumer fibers can be a challenge: Current state label laws require mattresses that contain post-consumer fiber to be labeled as used products. Lehner says about 70% goes into automotive acoustic insulation and carpet underlays.

“Cotton provides really good sound insulation under the carpet,” he says. “Most cars these days have a recycled pad in them.”

And Lehner says the advent of cars made with aluminum, like the new Ford F-150, means there’s a need for more sound insulation.

“You’re going to find more cars being made with aluminum bodies rather than steel, which in turn will use more fiber,” Lehner says. “That’s a very exciting side to this whole thing.”

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