Detailed Pillow Manufacturing Process
Pillow manufacturing is not a high-tech industry because it is easy to make, but just for ordinary cotton pillows, while the process of manufacturing memory foam pillows or microbead pillows is very difficult and involves a lot of materials and details, this memory foam pillows will require professional pillow manufacturers to produce. All aspects of pillow production must cooperate with each other to ensure quality requirements and time control. In this article, we will discuss the pillow manufacturing process in detail.
We have also writtern some posts about pillow filling material and tips to make a simple pillow.
Overview of pillow manufacturing process
The whole pillow manufacturing process does involve many steps, and the coordination between these steps makes the whole process time-consuming.
Sorting out all steps above, there are overall 7 steps
that we will mainly talk about as follows:
- Polyurethane foaming
- Fabric cutting
- Fabric sewing
- Case filling
- Closing the openings
1. Polyurethane foaming
Memory foam starts its life as polyurethane foam—a material first manufactured in the 1950s by adding water, halocarbons, or hydrocarbons to a polyurethane mix. Depending on the chemicals added and the way it is processed, polyurethane can form anything from car parts to spray liner, or in this case, one of the most comfortable sleeping surfaces the world has ever seen.
In the modern production of memory foam, a polyol is mixed with a diisocyanate and water. The foam rises like bread, with an open cell structure that helps give it its unique ability to spring back slowly from pressure. The introduction of gases into the initial solution creates a bubble matrix; vary the application of chemicals, and the size of the bubbles changes. A more open cell structure will have more give, and allow more airflow through the material.
2. Fabric cutting
The second construction in memory foam pillow manufacturing is the covering. A cotton-polyester or sturdy cotton fabric is shipped to factory in larger bolts which are treated there so that the casing that sewn can easily be separated while filling them.
These fabrics are then taken to tables for cutting apart after they are calendared. Heavy shears or machines for fabric cutting are used to obtain dozens of layers at a time.
3. Fabric sewing
The rectangular-shaped fabric stacks are then taken to sewing machines for grabbing and sewing them together. The machine operator sews two pieces of the fabric around the edges while leaving space for stuffing them later.
Mostly contents are attached while sewing the edges which are in tags form listing the details. The coverings are then turning inside out for the seams to be inside of the case.
4. Case filling
Before filling the case, to solve the odor problem common to most memory cotton, memory cotton pillow cores are placed on shelves for ventilation to reduce odor, and workers fill the jackets on special platforms.
6. Closing the openings
After filling the pillow casings, they are then taken to another platform where workers close their openings with the help of an industrial machine. Later, these filled casings are weighted on the same platform to ensure that all of them contain the required and predefined amount of batting into them.