Skip to content

We produce mattresses

How a mattress is made

Every day we work to ensure the comfortable sleep of millions of people. Our mattresses reach stores in nearly 30 countries around the world. We’re one of the largest suppliers of IKEA mattresses.

How do we do that?
We are developing very dynamically, in fact, today the structure of Ikano Industry enables us to control and give real influence on each stage of making a mattress. From the moment of designing a new product according to the parameters set by the customer, through laboratory tests, creating recipes and production of semi-finished products, assembly of mattresses, to reprocessing the foam both from production waste and from used mattresses and returning from consumers for reprocessing. Our goal is to produce mattresses that meet 100% of our customers’ expectations.

Start from research

The Research and Development Department of Ikano Industry is a team that:

  • tests innovative formulations based on new raw materials available on the market
  • finds applications for recycled polyols
  • implements newly developed products and technologies
  • supervises production tests and optimises process lines

Experienced technologists and laboratory research specialists study the physical and mechanical properties of PUR foam, latex and nonwovens and interlining.


We produce 4 families of foams with different densities and hardnesses, which in total gives 31 different types. On average, almost 40 pieces of 30 meters long blocks are produced per day, from which the so-called mattress forms are cut out. The pouring time of one block lasts several minutes. Then, the foam grows to a height of 1300mm, and the temperature inside the block, in the final stage, can reach even 160˚ C.

The next stage is seasoning. In order for the foam blocks to be used in the next production stage, they have to wait in appropriate conditions in our seasoning room for up to 120 hours, depending on the type. In Ikano Industry, we also produce Repoliol, which is a raw material for foam production from reprocessed foam production waste. We are the only factory in Europe with a plant for recycling flexible foam.

Polyester and polypropylene nonwovens production

We produce over 20 million polyester and polypropylene nonwovens annually, In the Nonwovens Production Area machine operators focus on two production lines: the production of polyester nonwovens and polypropylene nonwovens, i.e. interlining. Polyester nonwoven fabric is fluffy and gives covers additional softness, interlining is compressed and then we sew it on the inside of the cover to protect the nonwoven fabric against mechanical damage.

In some families of mattresses, a high-grade interlining forms the underside of the cover. It is an integral part of pockets, i.e. forms for spring mattresses. Both types of nonwovens are used not only in mattresses production but also in the furniture industry, filters production, gardening, automotive, construction and others.

In addition, in our Recycling Center, we recover some of the fibers for production from textile offcuts which are a by-product of the process of making covers.

Mattress Cover

The production process in the Sewing Area begins with the combination of components in the quilting process (knitted or woven fabric, nonwoven fabric and interlining). Experienced machine operators operate production lines consisting of modern industrial machines.

In the next stage, qualified seamstresses and machine operators complete and connect the remaining elements and this is how we come up with a ready cover.

The Ikano Industry sewing area is extremely comfortable and modern, equipped with an innovative transport system for semi-finished and finished products.

Mattres assembly

The mattress assembly department consists of several zones:

  1. The cutting zone, here the parts of the single mattresses are cut out of the foam blocks. At this stage, large blocks of foam are cut into smaller ones, and then cut into the so-called forms or boards which are the filling of foam mattresses.
  2. Gluing zone, where, depending on the type of mattress, formes are built. They have a different shape, thickness, cut-outs, they are made of different types of foam. And thus, mattresses of different firmness and price are produced.
  3. Packing zone. Here mattresses are put in covers, packed and as a finished product sent to the warehouse.

The mattress assembly process is fully automated. Modern robots improve ergonomics and work efficiency.

Quality control

Providing a comfortable sleep for millions of IKEA customers around the world is our top priority, so the department aims is to optimize products and processes. We systematically take steps to reduce costs of poor quality (COPQ), improve productivity, increase the availability of our mattresses in stores, and to share quality knowledge with employees.

Technological development

Modernization and improvements are necessary to maintain the required level of quality and to continuously increase the efficiency of the production process. The Technical Department at Ikano Industry is responsiblenot only for this area but also for developing process of obtaining energy from renewable sources.

Our technical departments:

  1. Design and Implementation Office, INDEMO where design engineers and automation specialists develop new equipment and machinery specifically for the unique needs of our production and improve existing resources.
  2. The Maintenance Department ensures the proper functioning and improvement of the current machinery and take care of the production infrastructure.