 |
Futon
Primer: Mattresses
By Joe Tatulli
Futon
Primer Part 1
The Mattress Part of The Equation
Introduction
The Futon Mattress
Is Maturing
As this category emerged in the late sixties and early seventies
the all cotton futon mattress was it. Today most manufacturers
will tell you that the cotton and foam futon mattress (in
some configuration) is the best (unit volume) selling product
in the market. Another trend has also emerged. Many futon
mattress companies are now making a softer to the feel, plusher
to sit on, premium futon mattress. These products are offered
at several higher-than-usual price points. This configuration
is targeted to a main stream consumer and the conventional
furniture stores they shop in. The dealers and consumers understand
this product better because it offers a look and feel they
are more accustomed to. “It just feels right,” is
an advantage when making the decision to buy a sofa or sofa
bed. Putting it plainly, both the manufacturer and the dealer
can make a better margin while giving their customer a more
comfortable product with more bells and whistles. The innerspring
futon mattress is also now a regular part of most manufacturer’s
lines. Still available are a number of hybrid products which
take their positions alongside the cotton and foam variations
and the 100% cotton futon. Cotton and wool futons, futons
with a tape edge and gusseted side panels (like conventional
mattresses), and futons encased in solid color, upholstery,
and designer print fabrics are presently not holding on to
as much market share as they had in the past.
Leather Covers Gaining in Popularity
Leather futon covers, which have been around
for years, are finally catching on. They have been well
received by consumers and several manufacturers are
well established in the market. Faux leather is also
coming on as leather continues to be a hot seller in
the home furnishings industry at large, with the trickle
down effect helping sales in the futon category.
|
Futon Mattress Configurations
To categorize each futon mattress configuration we will examine
it in relation to the following properties or criteria: weight,
firmness, rigidity, and flexibility.
Weight should be easy to figure out. What a futon weighs
does make a difference in the consumer’s experience.
Lighter is better as long as substance isn’t sacrificed.
Firmness is a measurement of the “feel” of the mattress
when used as a sleeping or sitting surface. Rigidity is the
ability of the futon to remain square-edged along the length
when in a sofa position, and flexibility is a measurement
of how well the futon applies itself to folding. Depending
on the end use of a particular futon mattress each of these
characteristics takes on a different level of importance to
the end use consumer. For example, if a customer is looking
for a futon mattress for sleeping only, perhaps on a platform
style bed, then rigidity is of little or no importance. But
the person who is purchasing a futon mattress for a sofa that
will only be used occasionally as a guest bed will put rigidity
high on the list because a more rigid futon will hold its
lines and not sag in the middle when in the sofa position.
The futon cover, therefore, will not wrinkle or look baggy
after prolonged use.
Futon Mattress Sizes
Futon Life Recommends
We recommend a minimum six inch 100% cotton
futon for use on any convertible futon frame. A thinner
mattress is acceptable, but only as a rolled-up, closet
stored, floor or tatami mattress. The six inch measurement
applies not only to the new product but also to how
thick it remains over its usable life. To measure thickness
go to the middle of the side, place a hand on the top
and bottom of the mattress and squeeze your hands together
gently. Measure the distance between your two palms.
If it is not a solid five inches the mattress does not
meet the minimum. Please remember that this method is
not very scientific since each person’s concept
of gentle is different. Close to five inches is good.
Three inches is not.
|
The 100% Cotton Futon
This is the traditional futon. Before we tackle the mattress
itself, I want to take just a minute to explain the process
of garnetting. Garnetting is done to create batting which
is then set down in layers, becoming the basis of the mattress.
Garnetting, in simple terms, is a process whereby individual
cotton fibers of various lengths are laid into a thin web
by combing. The garnett machine creates these webs and then
lays one web on top of another forming a very specific size
and weight cotton batt. The cotton batting for futons is made
mainly from cotton which has been deemed unusable for textiles.
Textile mills use the longer staple cotton which is separated
from the cotton seeds in the ginning process. The shorter
fibers, which are rejected by textile mills, are called gin
motes. These fibers, part of a blend that may include picker,
linter (the very short fibers that are removed from the seeds
before extracting the cottonseed oil), and sometimes even
some staple cotton become the batting or stuffing material
for the futon mattress.
To create the futon mattress cotton batts are laid out, one
on top of the other to the desired height (4”, 6”,
8”) and weight, and then the case (ticking) is either
pulled over the batting by hand or is attached to an automatic
stuffing machine which pushes the batting into it. (It should
be noted that manufacturers who use terms like “six or
seven layers” are missing the point. Six “layers”
can mean six four pound batts or six ten pound batts of cotton.
The term “layers” is therefore not acceptable, unless
it is qualified by layer weight.)
The case is then sewn or zippered shut and the futon is tufted.
In the past many of these futon mattresses were made by hand,
using tools which were employed by mattress makers of the
1930’s, 40’s, and 50’s. Some handmade futon
mattresses are sewn with the seam (to close the case) running
down the middle of the futon, while most machine made products
are end sewn or tape edged. Another popular closure is the
zipper. This method is very convenient for both the manufacturer
and retailer because it is so simple to use and does allow
examination of the filling inside the mattress. The tufting
may include up to forty tufts but a typical futon has about
twenty-eight to thirty-two.
Let’s consider our four properties. The 100% cotton
futon ranks as one of the heaviest. A twin futon weighs in
at about 38 lbs. to 45 lbs., a full from 48 lbs. to 55 lbs.
and a queen from 59 lbs. to 75 lbs.. Flexibility is excellent
and folding is relatively easy for the 6” futon, getting
progressively more difficult with the thicker (ten inch) units.
Rigidity is okay, with some sagging occurring in some units
after prolonged usage as a bi-fold sofa. The firmness level
starts out softer but becomes firmer after several months
of use. As the futon is slept on the cotton will compact and
become very firm, yet remain soft to the touch.
The Component Issue
Our industry is unique in many ways. But our
most unique feature is probably also our greatest obstacle
to eventual retail success and legitimacy. That feature
is the component issue. Because retailers have to, in
many cases, deal with three or more suppliers to put
a marketable unit on the floor, acceptance at main stream
retailers is an issue. Specialty retailers have always
dealt with the component issue as a feature and not
a handicap. But conventional dealers still struggle
with it because it doesn’t conform to the typical
buying process they are used to. Because of the special
disciplines and technical know-how required to manufacture
each of the three different components (mattress, frame
and cover) several “partnerships of suppliers”
(informal collaboratives of several independent companies)
have developed. These partnerships allow a particular
dealer or dealer chain to put together a program that
is coordinated with the partnership, or a variation
thereof, that delivers products in a more typical fashion.
|
The
Cotton & Foam Futon
Soon after arriving on the West Coast the futon began to
evolve. Not naturally of course but synthetically. Futon makers,
attempting to soften the firmness level of the basic cotton
futon, added a layer or two of medium to high density (1.5
PCF to 2.0 PCF) polystyrene foam. Some have opted to use flat
panels of foam while others are using convoluted or “egg-crate”
foam. This futon costs a little more to manufacture, but the
addition of the foam panels does several things which may
add to the marketability of the finished product. The overall
weight of the futon is lowered by 10 to 20 pounds, depending
on the mattress size. The level of flexibility is lower than
the all cotton, but not significantly enough to make a real
difference. The rigidity is excellent. The cotton/foam futon
is perfect for a bi-fold sofa-bed application because there
is no sagging. The firmness level is medium firm. As a retailer,
it is important to know the density of the foam in the mattress
as well as how much foam is used (1”, 2” etc.).
Too much foam and you lose the advantages of cotton as a foundation.
Several other types of foam are currently available to manufacturers.
Latex foam in varying degrees of “natural”, viscoelastic
or temperature responsive foam, and a product called Reflex™
foam made by Foamex, are hot right now. (There is a Foam Terminology
sidebar on the following page.)
| Futon Life Recommends
We recommend that every retailer have their
mattress supplier agree to sign a statement that they
(the manufacturer) have their 16 CFR Part 1632 documentation
on file and that they do comply with the Federal FR
Standard, and any appropriate State regulations.
|
The
Cotton & Polyester and 100% Polyester Futon
Polyester has been around the bedding industry for years,
and currently more and more futon mattress manufacturers are
using this synthetic fiber. Like foam, polyester is usually
an additional fiber, added to the all cotton futon. This addition
is handled in several ways. Some manufacturers place 100%
poly batting within the cotton batts during the construction
of the mattress itself, while others combine the polyester
with the cotton in the garnett and produce “blended”
batts (Wolf Corp’s Endura Blend is a fine example of
a cotton/poly blended batt). These futons are lighter by 10
to 15 pounds than the all cotton product, in fact several
companies produce 100% polyester mattresses that are half
the weight of an all cotton futon.
Remember, not all 100% polyester futons are created equal.
In fact, some of the units currently on the market have problems
with “bottoming out”. Keep this principle in mind;
(like our recommendation for cotton mattresses), a solid,
well stuffed six inch poly futon should be an excellent sit
and sleep cushion. Ask manufacturers about “densified”
polyester. This product is heat treated to condense the fibers
into a pre-compressed form that will hold its loft longer
than regular poly fill. Flexibility is good. Depending on
the nature of the polyester fill itself, and the cotton to
poly ratio, rigidity may go from fair to excellent, i.e.,
the more polyester, the more rigidity. The firmness level
is definitely softer than the cotton/foam futon, and resiliency
(the ability to maintain loft) is also higher than the all
cotton mattress because of the nature of the poly fiber itself.
Branded fibers that are even more resilient are very expensive
compared to the cost of cotton, but they do maintain their
loft better too.
One important advantage of using synthetics is compliance
to flammability laws. At this time FR foams and poly-cotton
blends help manufacturers meet the federal FR cigarette test
standards. Another big advantage is weight. Lower weight means
lower shipping costs and a much more sellable product at the
retail level, as the consumer attempts to move the futon around
or change the cover.
There is also a polyester product on the market that is recycled.
Rising Star Futon of Bend, Oregon has an exclusive contract
to produce the WellSpring™ fiber from re-cycled pop bottles.
The clear bottles produce a white fiber and the green tinted
bottles produce a green fiber. The process involves melting
down the recycled bottles and extruding new fibers.
The Cotton & Wool
and 100% Wool Futon
If you have ever heard the expression “Sleeping on a
cloud,” and you wanted to actually feel that sensation,
then the all wool futon is for you. Wool is extremely resilient
and therefore provides great support. Wool is a naturally
flame retardant fiber, thereby allowing it to pass the FR
Standard cigarette tests. Wool is light. A six inch thick,
full size 100% wool futon weighs a mere 38 pounds as opposed
to an all cotton weight of about 56 to 60 pounds. Rigidity
is superior but flexibility is almost non-existent. A cotton/wool
futon, with a batt of wool top and bottom, may offer the best
of both worlds. Permanently crimped wool is available and
several products have been given the endorsement by the Wool
Bureau to use the “Wool Mark”, the officially licensed
logo, designating that the product has passed a battery of
tests concerning the quality of the fibers as well as the
level of fiber migration through the ticking material. The
cost of wool is high ($4 to $5 per pound for washed New Zealand
and $7 per pound for mechanically crimped wool), but the quality
of any finished product, along with the high consumer acceptance
of the wool mark make it a viable alternative in this growing
product category.
The
Innerspring Futon
Today it seems that every mattress company making futon style
mattresses has an innerspring unit in their line-up. Gold
Bond Futon of Hartford, CT, introduced their CottonCoil™
futon several years ago. Two years ago the Simmons Company
once again entered the futon market with United Sleep Products
making their branded pocketed coil Beautyrest® futon mattress.
The CottonCoil employs a more traditional interlocking spring
unit which is remarkably flexible. Wolf Corporation, August
Lotz, Otis Bed, and many others are also producing innerspring
futon mattresses. The market for these products seems to be
strongest in the traditional bedding stores where they understand
the innerspring concept. These units are also slightly more
expensive than the other configurations and tend to be a little
heavier than most other futons. They also offer a certain
level of comfort only attainable with an innerspring construction.
Another factor to consider is the effect of years of marketing
already done by the innerspring industry. Consumers understand
the concept well enough to buy it now. These units also offer
the futon industry another cross-over product into the more
traditional home furnishings industry. FL
Back to Top How
to Buy a Futon
1999 Futon Life. All
rights reserved. No part of this document may be reprinted,
photocopied, or duplicated without the express written permission
of the author.
|
|
