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	Multi Needle Quilt Machine Layers of quality foam (and fiber also in pillow top models) are fed into the machine. Here many needles work together to stitch these layers to the mattress fabric, forming a single quilted pad. This quilted pad is then either cut into twin, full, queen, king or special size panels to put on the top and bottom of the mattress or the quilted pad is spooled into large rolls holding up to 60 yards to be cut later into sized panels.

	Mattress Building A bare mattress spring is selected based on the size and the model of the mattress to be built. This unit is placed on a specially designed table. A thick layer of cotton padding is placed over the coils. Cotton is used to enhance the durability, comfort and tailoring of the mattress. Padding materials will vary based on the type of mattress being made (i.e. Plush, Extra Firm, or Pillow Top). A layer of convoluted foam is placed on top of the cotton. A quilted cover sewn on the multi-needle quilt machine is then placed on top of the padding layers and attached to the coils to prevent shifting of the padding materials.

	1-6   The tape edge operation is considered to be one of the most difficult jobs in a bedding plant.   The operator needs to sew the top quilted mattress panel to the side border using a binder, walking backwards as he does so.   In the course of a day, the operator will walk about a mile backwards.   After one side is done, the operator flips the mattress and does the other side. A pillowtop style mattress needs to be bound twice on each side.

	1-3   The sewing machine operator takes a pre-cut piece of non-skid material and sews it to a quilted border using a binder.

	A well-built box spring is chosen based on the model to be upholstered. Box springs vary based on the amount of wood and wire used. The box spring unit is placed on the pre-upholstery table and corner straps are attached. An insulator pad is placed on top of the unit and wrapped on all four sides. Next, the cover is fitted over the whole unit. The box spring is then flipped over onto the upholstery table and compressed about 1 1/2". The cover is then attached to the frame using a pneumatic stapler. A layer of non-woven material is then stretched across the box spring and secured to produce a dust barrier.