The kind of foam your mattress is made with can’t solely influence the general high quality of your sleep, but additionally your general well being. Some foams are made with toxic chemicals which you should not sleep on each evening. Thankfully, many mattress manufacturers create and use non-toxic foams of their mattresses. Here is what to search for when buying non-toxic mattresses and why it must be essential to you.
The CNET sleep group had the chance to go to the 3Z brand mattress manufacturing unit in Glendale, Arizona. In the course of the tour of the 600,000 sq. foot facility, the CEO taught us how 3Z makes all of its beds – six distinctive manufacturers – in-house. A few of 3Z’s best-known mattresses embrace the Brooklyn Signature Hybrid Bedding, Helix Midnight Luxury, Leesa Sapira Chill Hybrid, Nolah Original 10 inches, Natural Birch And Hybrid Elite Bear. We determined to learn the way a manufacturing unit that produces six totally different manufacturers provides every mattress a particular look.
Be taught extra: Best mattresses of 2024
How is foam totally different?
One of many fundamental explanation why one mattress might look totally different from one other is the kind of foam used. For instance, the Tempur-Pedic Breeze Pro Mattress feels radically totally different from the Nolah Unique 10″. Whereas the typical Breeze Professional mannequin can be barely firmer than the Nolah Unique, Tempur-Pedic makes use of dense reminiscence foam in its mattresses. The froth within the Nolah Unique is a impartial polyurethane foam (made on the 3Z manufacturing unit) This sort of foam is lighter and extra forgiving, that means it does not really feel such as you’re caught within the mattress. poly nonetheless relieves stress, nevertheless it makes you’re feeling caught within the mattress such as you’re sleeping extra on the mattress than on it.
All-foam beds, just like the Nolah Unique, are constructed with a number of layers of froth, every barely totally different. Some foam layers are firmer and used for assist, whereas others are consolation layers and supply stress reduction. The chemical composition of the froth determines its density, firmness and really feel.
What are the various kinds of foam utilized in mattresses?
In addition to polyurethane foam, different varieties of foam embrace:
- Reminiscence foam
- Reminiscence foam
- Copper-infused foam
- Excessive density foam
- Latex foam
Be taught extra: Guide to Mattress Types: Materials and Things to Consider
How is foam made?
Consider it or not, making mousse is the same course of to creating a cake. Briefly, you add the elements, combine and watch the product rise. Though the chemistry behind foam is not so simple as cooking, this analogy breaks down the froth casting course of into easy phrases.
When Owen and I watched the method, it felt like we had been in an episode of How It is Made. We had been as shut as attainable; we actually might have reached out and touched the liquid spilling onto the conveyor belt.
Merely put, John Merwin, CEO of 3Z, describes the froth casting course of as “mixing liquid chemical substances in exact proportions.” As soon as these chemical substances are mixed, they react and rise when the froth is transported on a conveyor belt.
“This combination is rigorously monitored to make sure uniformity and high quality because it rises and hardens right into a stable foam block,” says Merwin. Though it solely takes a couple of minutes for the brand new foam to rise, it takes a number of hours for it to totally harden. As soon as the froth is stable, it’s then reduce into actual layers to be used in any 3Z mattress.
Should you thought like me that the colour of a foam decided its really feel… that’s really improper. On the manufacturing unit we had been instructed that the rationale one piece of froth is grey, for instance, and one other blue is just to tell apart them.
It’s also essential to notice that 3Z foam is CertiPUR-US licensed. This implies the froth is protected, fiberglass-free and made with out poisonous chemical substances corresponding to “ozone depleters, formaldehyde”. [or] heavy metals. » This additionally signifies that foam with this certification “meets strict requirements for content material, emissions and sustainability,” says Merwin.
The one different foam certification is GOALS (International Natural Latex Customary), however this solely applies to latex foam. 3Z affords beds containing GOLS latex foam (i.e. the Natural Birch), however it’s not accomplished internally. The method of constructing latex foam may be very totally different from that of pouring polyurethane; this requires sure particular uncooked supplies, procedures and machines.
Video: Foam Pouring in 3Z Mattress Manufacturing facility
Watch my fellow mattress professional, Owen Poole, and I discover the 3Z manufacturing unit and perceive how they make its foam.
3Z mattress foam
I’ve examined over 70 mattresses through the years, and a few beds from 3Z are a few of my favorites. I attribute this largely to the supplies he makes use of; primarily moss.
3Z is exclusive in that few mattress manufacturers in the USA produce their very own foam or, even fewer, have a manufacturing unit that makes its beds in-house. Merwin says: “Our foams are made with meticulous care and a spotlight to element. What units our foam aside is that it’s poured in-house, giving us full management over the standard of the ultimate product. He continues: “It additionally permits us to create new foam variants unique to our manufacturers.”
Earlier than the journey, Poole and I had been very curious about how 3Z made its beds distinctive if all of the assembled supplies got here from the identical place. To this, Merwin explains: “The distinction in really feel between them is because of the totally different formulations and densities suited to every mattress mannequin. We modify the composition and construction of the froth to attain particular ranges of firmness, assist and luxury to fulfill the wants of every mattress. distinctive necessities. »
Whereas 3Z makes a number of “common” foams used throughout a number of beds and types, Merwin says “a lot of the foams we pour are tailor-made to every model” and “every of our manufacturers has a definite identification… [that] is backed by the supplies used to make every model’s mattress assortment.
I got here away from my manufacturing unit tour with a greater understanding of froth and the way it impacts the texture and firmness of your mattress.
Why this could matter to you
Should you’re not within the mattress business like me, watching somebody pour foam may not make for a enjoyable afternoon. Nevertheless, in case you worth a high-end, high quality mattress, the development of your mattress’s supplies nonetheless applies to you. When on the lookout for a brand new mattress, make sure that its foam is Certi-PUR US licensed to make sure your mattress is freed from poisonous chemical substances.
Second, the kind of foam in your mattress determines the texture and firmness. In case you are on the lookout for stress reduction however are a horny sleeper, I like to recommend memory foam. Nevertheless, in case you like the texture of a dense, conventional foam, I like to recommend memory foam beds. Impartial polyurethane foam is a contented medium that appears to please most sleepers.
Should you purchase a mattress from 3Z, you may relaxation assured that the froth is made in-house, freed from dangerous chemical substances, and designed particularly for consolation and assist. Merwin says: “We’re consistently innovating and creating new varieties of foam that set new benchmarks within the bedding business. »
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