Today’s border fabric, fiber, nonwoven and tape producers are helping bring beds together.
The phrase “Blest be the ties that bind” originated from the title of a hymn written in 1782 by English minister John Fawcett and featured in the classic Thornton Wilder play “Our Town.”
The hymn and the familiar phrase it spawned symbolize the importance of forming the connections that build a tight-knit community. The phrase also aptly sums up the contribution of border fabric, fiber, nonwoven and tape producers to the bedding industry.
While some cynical few may view tape and fibers as commodities, today’s tape and fiber producers are digging deep to find new ways to improve their products’ benefits, incorporate innovation and style, support sustainability and circularity initiatives, and add value to bedding systems and the community they bring together, both literally and figuratively.
Given that heightened visibility, BedTimes reached out to discover what innovations and trends in fabric, fiber, nonwoven and tape producers see on the horizon.
Driving Innovation in Bedding: Advancements in Fabrics, Fibers, and Nonwovens
Many of today’s tape and fiber producers are developing innovations at either end of the technological spectrum — some draw on natural fibers while others use advanced technologies to enhance quality, performance and durability.
A “bespoke mechanical crimping process” makes the wool fiber springier and more resilient. This process offers multiple benefits, including natural temperature regulation, moisture wicking, hypoallergenic properties, comfort and durability. Mechanically crimped wool is featured in various bedding applications, including nonwoven Joma Wool batting; needle-punched, naturally fire-retardant Joma Memory Wool; and Joma Wool Pearls loose fill.
Like John Marshall & Co., The Jones Family of Companies offers sustainable natural fiber blends. One is a stratified FR construction that integrates soft polyester or cotton layers to enhance comfort and streamline quilting operations. Another uses jute/cotton and hemp-based layers to align with eco-friendly consumer demands. A third adds compression-resistant bottom pads for improved mattress durability and structural integrity.
“These innovations improve the durability, comfort and functionality of sleep products while reducing production complexity,” says Scott Butler, president of the Humboldt, Tennessee-based nonwoven manufacturer.
Hillside, New Jersey-based cut-and-sew manufacturer Jomel Industries takes another tack. “At Jomel, we continuously invest in state-of-the-art technology to better serve our customers’ needs and enhance product quality,” says CEO Phil Iuliano.
Jomel’s recent investments include converting equipment that can customize specific widths and lengths to customers’ requirements and a 120-inch automated cutting machine that reduces fabric waste and maximizes efficiency. Its use of premium materials like Hi Loft fire barriers and Dacron/polyester quilting helps improve the durability and longevity of sleep products, Iuliano says.
Lenzing, Austria-based Lenzing Group combines natural resources like wood and botanic fibers with advanced technology to create innovations such as Lenzing Ecovero, a black viscose designed to meet current ticking fashion trends. In a joint project with North Carolina-based fabric supplier Culp Inc., Lenzing combined its Tencel lyocell fibers with Germany’s Suedwolle Merino wool to create a two-fiber mattress ticking. Lenzing is also working with Ateja in Indonesia to develop a new fashion ticking using Lenzing Ecovero black fibers and with Turkish ticking manufacturers to create a 100% Tencel mono-material mattress ticking (mono-materials are a more sustainable and environmentally friendly choice than synthetic materials or natural/synthetic fiber blends). Lenzing has also re-introduced its wood pulp-based lyocell powder to the U.S. market to improve moisture management in foam mattress production.
“Lenzing’s cellulose and fibers are their starting point to value creation,” says Walter Bridgham, senior business development manager for the Americas. “Together with our customers, we develop solutions that add value to their businesses and products.”
Eagan, Minnesota-based mattress tape supplier Bechik Products Inc. takes a back-to-basics approach, focusing on design, quality and performance in the 350 SKUs in its tape line, ensuring ease of application, colorfastness and uniformity using high-end materials.
“Today’s mattress panels often have a decorative border or a bit of pattern,” says Bill Simon, president of Bechik. “As a result, producers are looking for tapes that will complement their ticking and borders — not compete with them. They want quality products at a good price, backed by the very best service.”
Sustainability in Focus: Eco-Friendly Innovations in Bedding Components
As the bedding industry continues to make significant strides toward sustainability, border fabric, fiber, nonwoven and tape producers are employing practical solutions to solve environmental challenges, improve production efficiency and meet the growing demand for eco-conscious production practices, transparency and authenticity.
John Marshall & Co. answers these challenges by using natural alternatives and mono-materials like Joma Wool, highlighting its durability, biodegradability, recyclability and renewability as essential attributes in reducing environmental impact and aligning with the circularity movement.
The company’s commitment to transparency is reinforced through its active support of certification programs such as Oritain, Oeko-Tex and New Zealand Farm Assured to verify product origins, traceability, safety and animal welfare standards.
“Joma Wool is produced using sustainable and environmentally friendly practices, making it a great choice for
eco-conscious consumers,” Brilleman says. The company’s efforts also extend to repurposing waste wool and minimizing waste through sustainable collaborations.
Jomel Industries integrates sustainable practices into its operations, investing in machinery like its 120-automated cutting machine to minimize waste, maximize fabric utilization and reduce energy consumption and material costs. The company also prioritizes using nonwoven materials and other alternatives that enhance durability and extend product lifespans.
“Overall, our sustainability initiatives have helped improve the efficiency, production and cost-effectiveness of bedding production while also reducing our environmental footprint and supporting our customers’ sustainability goals,” Iuliano says.
Jones’ sustainability efforts focus on reusing post-industrial textile byproducts and developing eco-friendly, plant-based fibers like jute and hemp. Energy-efficient production practices, such as lean manufacturing and ISO-certified processes, help the company minimize waste and optimize resource use. Its localized manufacturing facilities also help reduce transportation distances and vehicle emissions.
“These measures enhance efficiency, lower production costs and meet growing consumer demand for sustainable solutions,” Butler says.
Lenzing creates products derived from renewable sources and processed with resource-conserving technologies to “redefine circularity and drive positive impact for a more regenerative environment,” Bridgham says.
Lenzing’s lyocell, modal, Ecovero viscose and Refibra fibers are certified bio-based, compostable and biodegradable. They are made from controlled or certified wood sources combined with pre- and post-consumer textile waste and recycled cotton, which helps further reduce reliance on virgin materials. A selected range of Lenzing’s Tencel lyocell and modal fibers has also achieved ClimatePartner certification as part of a five-step climate action plan.
Simon of Bechik acknowledges that using recycled mattress yarn in tapes is currently cost-prohibitive but the company is always looking for opportunities to minimize waste and adopt the latest developments in mattress recycling, sustainable sourcing and circular production. “With further innovation and efficiencies by yarn producers, the ability to produce cost-effective (recycled) mattress tape may emerge in the near future,” he says.
The Future of Bedding: Emerging Trends and Innovations
The bedding industry is poised for transformative innovations over the next few years as companies adapt to sustainability demands and evolving consumer preferences.
Brilleman foresees the increasing use of natural alternatives such as Joma Wool and the growing importance of transparency and authentic sustainability over misleading marketing.
“In today’s global market, consumers are becoming increasingly conscious of the origins and authenticity of the products they purchase,” Brilleman says. “Brands that can offer unequivocal proof of the origin of their goods not only gain a competitive edge but also establish a foundation of trust with their customers.”
Iuliano forecasts a significant shift toward U.S.-based manufacturing, spurred by supply chain security, increased import tariffs and growing consumer demand for domestically produced goods. He also sees “an increasing demand for higher-quality products, faster lead times and more sustainable options … not just in the materials used but also in the production processes.”
“I believe the future of the bedding industry will see greater collaboration across the supply chain, from raw material suppliers to manufacturers,” he added. “This collaboration will be essential to overcome challenges like shifting consumer preferences and regulatory changes.”
Butler has his eye on sustainability. “Emerging trends include a greater focus on natural and sustainable materials in mattress design and increased interest in multipurpose fiber solutions for both bedding and furniture,” he says.
Butler believes that key areas of focus for the industry to adapt to these changes include encouraging widespread adoption of sustainable practices and materials, providing cost-effective and efficient solutions without compromising quality, and partnering with design teams to create innovative, market-responsive products.
Simon emphasizes the trend toward larger tape widths to accommodate thicker mattresses while maintaining quality and cost-effectiveness.
“Some mattresses have gotten so thick and with those heights, they’ve become more difficult to sew,” Simon says. “I think 1 ½ inch is going to be where the industry settles, however, and when they can, producers will try to make a narrower tape work because of the cost savings.”
Bridgham notes the importance of circularity as mattress recycling becomes more common. Like Iuliano, Bridgham also identifies a need for industry collaboration, proposing an innovation hub that brings together supply chain participants to explore sustainable solutions.
“There is so much opportunity for industry and innovation collaboration if only the appropriate space were created,” Bridgham says.
