Stronger bonds, better sleep: Bulk adhesives in the mattress industry

Getting a good night’s sleep starts long before your head hits the pillow. A restful night begins in the factory where a mattress is made, with every layer engineered for comfort and support, and adhesives are a key but often overlooked component in achieving this.

For manufacturers, the choice of adhesive can make all the difference between a mattress that stands the test of time and one that fails to deliver. In a market increasingly driven by quality, getting adhesive selection right is crucial for ensuring high quality, streamlining production and ultimately, better sleep for customers.

Hidden challenges of mattress assembly

Manufacturing mattresses is a complex operation. Every mattress is composed of multiple materials including foams, fabrics, spring units, and more. Each of these materials has its own bonding requirements, and conventional adhesives have historically faced challenges when used for bonding them.

Water-based adhesives, for example, can lead to moisture being trapped within the mattress, resulting in a higher risk of mould growth. Solvent-based adhesives, while effective, emit volatile organic compounds (VOCs) that pose health risks to workers and require costly ventilation and safety measures.

Production speed presents another critical concern. In a competitive industry, slow-acting adhesives that slow the assembly line can quickly result in bottlenecks. Water- and solvent-based adhesives often need lengthy drying or curing times that make it difficult to keep up with demand or respond to custom order requests. Additionally, the growing complexity of modern mattresses, with intricate layers and advanced materials, demands adhesives that can bond with a wide range of substrates quickly and reliably.

The bulk hot melt solution

Our bulk hot melt adhesives are engineered to address these very challenges. Unlike traditional adhesives, hot melts are solids at room temperature and become liquid when heated, enabling fast, precise application and near-instant setting. This rapid setting to a solid state also removes the risk of mould formation. As a result, bonded components can be moved along the production line almost immediately, increasing throughput and reducing production costs.

This technology has the added benefit of a VOC-free formulation. Our adhesives release no harmful contaminants during application, eliminating the need for personal protective equipment or extraction systems and creating a safer, more pleasant working environment.

Stronger bonds

With strength and reliability being non-negotiable in mattress assembly, our bulk hot melt adhesives offer the ideal solution, standing up to repeated compression to ensure long-lasting performance. Sprayable solutions like Tecbond 425-PL offer high strength and flexibility even under extreme tension and set with faster cooling and reduced material damage. As a result, whether you are bonding foam to foam or attaching fabrics and non-wovens, our adhesives deliver consistent, durable results.

Better adhesives, better mattresses

The quality of a mattress is only as strong as the bonds that hold it together. With Power Adhesives’ bulk hot melt technology, manufacturers can overcome traditional barriers to deliver mattresses that excel and rest easy knowing that they are delivering a better sleep for everyone.