Wolf Overcomes Independent Performance Testing

The machinery in the plant consists of three garnetting units. Two older lines and a new state-of-the-art unit that went into operation only last year to produce Wolf's own proprietary cotton futon batt called Endura™. Without getting too technical a garnett machine allows its operator to produce batting of various cotton and synthetic blends, and also various lengths, widths and weights. It all starts with blending. "This new unit is completely computerized," said Wolf. Four large bins are filled with various fibers. Wolf explains Endura cotton's mix of fibers which includes a blend of two recycled polyester fibers, a natural brown staple cotton and two other cotton fibers. "We take our experience at buying fibers and then translate that experience into consistency through technology," he said. The churning of the blending units ends with them dropping a very specific amount (by weight) of fiber onto a moving conveyor belt. We are standing in front of a well protected computer monitor as Wolf points to the numbers on the screen. Over the din he explains. "Each of these four hoppers is programmed to release a very specific amount of fiber on to the conveyor. The computer remembers if each one is a little over or a little under and compensates for it on the next drop. By doing this we get a uniformity of product that is unsurpassed in the garnetting business." The conveyer then moves through a cleaner to remove field trash (cotton plant pieces) and then on to the flame retardance process. Wolf uses a method known as tumble blending. This method sprays a fine mist of oil on the fibers and then applies 10% boric acid to the fibers. "This method holds the boric to the batt no matter how much of a beating it takes," said Wolf.

	The performance test uses a machine to put a unit through 100,000 use cycles, or ten years worth of abuse.
	"Our unit did not have a single failure. No tufts broke, there was no pocketing of foam or fiber into the spring unit, and not a single spring was even slightly damaged," Gary Cohen said.
	Here is a final look at what Wolf is achieving in performance testing.

As Wolf began to produce futon mattresses he also realized that softness was a real issue. "We discovered that the major complaint about cotton futon mattresses, made primarily, is that they are too hard for many people," said Wolf, "With Endura we have solved that problem, without eliminating the cotton." So, unlike the all polyester or polyester wrap product out there, Wolf has blended the polyester into the batt to provide softness and resiliency, with the cotton there doing its job of providing the substance and body. Gary Cohen, National Sales Manager for Wolf, was quick to point to an independent lab test conducted recently by the company to prove its theory true. "We put an innerspring futon mattress through its paces and we passed with flying colors," said Cohen. Cohen supplied us with pictures which appear in a side bar elsewhere in this article. The performance test uses a machine to put a unit through 100,000 use cycles, or ten years worth of abuse. "Our unit did not have a single failure. No tufts broke, there was no pocketing of foam or fiber into the spring unit, and not a single spring was even slightly damaged," he said. Cohen was visibly excited with the condition of the Endura fiber itself. "This successful test gives us a great platform to work from," said Cohen, "We have a product that works when people are looking for true sitting and sleeping comfort and also a product that has the component fibers every futon specialty store wants and every furniture and bedding store understands." Cohen also shared his desire to provide futon mattress retailers with some excellent POP and signage. "We have developed a hang tag program for retailers that will help them sell and will also educate consumers who are trying to sort out what to buy. They will outline the features and benefits of all our products, including the thirteen different styles that use Endura™," he said.

continues on next page