Production Process

Crib Mattress Production Process

Every crib mattress begins with customized sample development and moves through material inspection, quilting, cutting, sewing, quality control, assembly, packaging, and shipment. By carefully managing every step, we help ensure consistent quality, safety, comfort, and reliable performance for babies and families.

How We Make It

Our Manufacturing Steps

Sample Making

Using our foldable POE air fiber crib mattress for the Japanese market as an example, we develop samples based on the customer’s required dimensions. We customize the POE air fiber core and select quilted cotton fabric and spacer mesh fabric for the mattress cover. During development, we also evaluate material utilization, production efficiency, and manufacturing stability to ensure a smooth transition to mass production.

Pre-Production Meeting

Before production begins, department managers review product specifications, workmanship requirements, and quality standards together. Detailed SOPs are prepared for every production stage to reduce errors and ensure consistent execution throughout the manufacturing process.

Material Inspection

Because the mattress cover uses a three-layer quilted structure, all fabrics are inspected before quilting. We check for stains, loose yarns, fabric damage, and other defects to ensure only qualified materials enter production.

Quilting

After inspection, qualified materials move to the quilting process. We closely monitor quilting speed, thread quality, machine condition, and equipment cleanliness to ensure stable workmanship and maximize production yield.

Cutting

Approved patterns are provided to the cutting department before production. We use automatic cutting machines to improve precision and maintain dimensional tolerances within approximately 5mm.

Cut Panel Inspection

Every cut panel is inspected individually after cutting. Any defective, stained, damaged, or incorrectly cut components are removed before sewing begins to prevent downstream quality issues.

Sewing

The mattress cover passes through multiple sewing operations, including overlocking, binding, and zipper installation. Each worker focuses on a specific process to improve efficiency and workmanship consistency. Experienced team leaders continuously monitor product quality throughout production.

In-Process Inspection

Our technical supervisor and production manager conduct inspections three times daily to identify and resolve issues quickly. The sales team also performs an additional daily inspection to ensure smooth production and consistent quality standards.

Quality Inspection

Each mattress cover undergoes two independent quality inspections. We verify dimensions, sewing strength, appearance, cleanliness, and overall condition to ensure products meet established quality requirements.

Needle Detection

Both the mattress cover and POE air fiber core pass needle detection before assembly. We also conduct daily inventories of needles, scissors, tweezers, and other sharp tools, with detailed records maintained for every broken needle incident.

Assembly

After inspection, the POE air fiber core is inserted into the mattress cover. Our team carefully checks the fit between the core and cover to ensure a smooth appearance and stable product structure.

Packing

All hangtags, polybags, cartons, suffocation warning labels, and packaging materials are prepared according to standardized packaging SOPs. Packaging takes place in a dedicated enclosed area that is cleaned daily to maintain product cleanliness and packing accuracy.

Shipment

Before shipment, all export cartons are inspected to ensure they are strong, intact, and suitable for transportation. Delivery vehicles are cleaned and checked before loading to help protect products throughout transit.

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