NEWS RELEASE
BOCA RATON – FL (August 5, 2026). Live Comfortably, North America’s largest utility bedding manufacturer, has announced the initiation of mattress pad and protector production at its plant in Martinsville, NC. The plant will initially manufacture pads and protectors mainly for the hospitality markets and a handful of retail accounts. But the line will be capable of supporting Live Comfortably’s entire US retailer base. The domestic production line establishes Live Comfortably as the only large-scale US manufacturer of poly fill mattress pads and protectors.
“We acquired domestic mattress pad and protector capabilities and equipment with Downlite. Our initial assumption was that we would follow our recent practice and convert to importing this category as finished goods from overseas,” said Brian Cassady, CEO of Live Comfortably. “But certain Downlite retail accounts expressed a clear desire for US-made products. Obviously, we take customer feedback very seriously. So, I instructed Ken Woung, our COO, to critically evaluate the production process with an eye toward satisfying customer demands without sacrificing quality or margins.”
“We took on the challenge as the latest step in our strategy of leveraging our US manufacturing excellence,” said Woung. “As we analyzed Downlite’s capabilities, which were already strong, we became convinced we could improve upon them and continue to efficiently produce in the US.”
The new production capabilities stem from the transfer of selected equipment and knowledge acquired from Downlite in March. The start of production coincides with the closure of the now former Downlite plant in Monroe, NC. It also marks the completion of Live Comfortably’s absorption of all of Downlite’s manufacturing operations into Live Comfortably’s US factories.
“The headstart that Downlite’s expertise gave us is a huge benefit,” said Bryan Vaughn, Live Comfortably’s VP of Manufacturing. “But we are also greatly aided by our own in-house experience with domestic mattress pad manufacturing. Springs Global manufactured mattress pads for over 20 years in our Martinsville plant until 2019. Some of the personnel who managed Springs’ production are still with us. Their expertise has allowed us to take all the great practices that Downlite had developed and add some knowledge to generate incremental improvements.”
Live Comfortably’s new production line in Martinsville will have the capacity to produce 1.3 million mattress pads annually.
“Even though this is not completely new to our management team, there is always a learning curve, even it if just involves reacclimating a team to a process at which they used to excel,” said Cassady. “So, our initial production will serve those customers who currently demand US manufacturing. But ultimately, we would like to use this unique domestic production capability as a competitive differentiator in the market. We hope to convince a wider group of customers of the value of nearshoring from us vs. reliance on a long supply chain involving imported finished products.”
About Live Comfortably
Live Comfortably is the largest bed pillow, comforter and mattress pad/protector manufacturer in North America. It serves consumers through online sales, partnerships with the largest retailers in North America, and distributors to major hotel and hospitality chains. The company has licensing agreements with the strongest brands in the home furnishing industry, including Serta, Ralph Lauren, Kate Spade, Nicole Miller, Good Housekeeping, Tommy Bahama and Pendleton. It also owns the Restful Nights, Downlite, I AM and Protect-A-Bed brands. Live Comfortably’s manufacturing and distribution facilities in California, North Carolina, Texas and Virginia span two million square feet. It has the capacity to produce in excess of 120 million pillows annually. Live Comfortably also operates in-house materials sourcing offices in China, India and Pakistan. For more information, visit livecomfortably.com. Media Contact: [email protected]
