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Bedding investment boom: Producers betting on U.S. market with new facilities (Mesquite's Elements Intl.)

HIGH POINT — Bedding manufacturers are making big bets on the U.S. market by making significant investments in new facilities to keep up with current demand and continue the growth trajectory that last year delivered.

Currently, there is more than 2 million square feet of new manufacturing space either recently opened or underway and set to open later this year. In addition, there are at least three other bedding producers with plans for expanding their footprints; however, they are still in the negotiating stages with builders and developers.

Brooklyn Bedding, Mlily USA, bedding newcomer Elements International, Corsicana, Spring Air International, Soft-Tex International and Bedding Industries of America, the flagship licensee of Eclipse International, have all either opened factories or are in the process of opening them now.

Tempur Sealy has announced a $150 million capital investment plan for the next three years that calls for expanding three foam facilities and building a new foam operation in the U.S.

Some executives see the timing as perfect given the impact antidumping duties have had on imported mattresses, especially from China, Vietnam, Malaysia, Cambodia, Indonesia, Serbia, Thailand and Turkey.

The latest figures from the U.S. International Trade Commission showed that mattress imports in December dropped 63% — 511,000 units — marking the second month in a row imported mattresses posted a decline.

Much of the two-month decline can be attributed to the antidumping duties impacted the seven countries other than China that went into effect in November.

Elements International jumped into the bedding category last fall, and the company is currently building a new 175,000-square-foot facility in its hometown of Mesquite, Texas, giving it the capacity to produce 1,200 mattresses a day. The factory is scheduled to open in the second quarter of this year.

The company’s move into the bedding category was spurred by customer request, OEM demand and the ability to deliver a diverse product offering to new and existing retail customers, said Jeff Quinn, Elements Sleep vice president, adding that the timing makes sense for the company.

“We see the recent decline in imports as a significant driver for the industry,” Quinn said. “The key driver for Elements is our continued commitment to enter categories that make sense where we can bring added value and service to our dealer base while attracting new customers.”

Brooklyn Bedding recently broke ground a nearly 650,000-square-foot facility in Glendale, Ariz.

Bedding manufacturer and retailer Brooklyn Bedding broke ground last week on a nearly 650,000-square-foot facility in Glendale, Ariz. The company is investing more than $72 million on the factory that will open in December this year and triple the company’s current manufacturing footprint.

The facility will house the company’s headquarters and manufacturing, and it allow the company to be almost completely vertically integrated. Upon completion, the company says it will add up to 150 employees over the next two years. Brooklyn Bedding currently employs more than 250 in the Phoenix area.

“Brooklyn Bedding has come a long way from the early days of selling overstock mattresses to now be in a position to triple mattress production,” said John Merwin, owner and CEO. “Over the years, I’ve been asked to define our journey as an American-made brand.

Mlily USA’s new factory in Goodyear, Ariz.

Arizona has attracted Knoxville, Tenn.-based bedding producer Mlily USA for its West Coast manufacturing center. The company is in the process of outfitting a nearly 650,000-square-foot factory in Goodyear, Ariz., another suburb of Phoenix. The company is modeling the factory after its factory in South Carolina and will house mattress manufacturing, foam pouring and spring production operations. When at full capacity, Mlily’s Arizona factory will employ 300 and have the capability to produce 6,000 units a day, the company said

“We are seeing significant growth both in our branded products and in our private-label contract business,” said Stephen Chen, president of Mlily USA. “The additional capacity will allow us to maintain our growth trajectory and continue to fulfill the growing demand for domestic-made mattresses, crafted by American workers.”

Soft-Tex International’s new 165,000-square-foot factory in Sugar Land, Texas, gives the company 750,000 square feet across the three locations.

Mattress and sleep accessories manufacturer Soft-Tex International opened its 165,000-square-foot factory in Sugar Land, Texas, earlier this month, adding to two other facilities located in Waterford, N.Y., and Charleston, S.C. The new operation gives the company 750,000 square feet across the three locations.

The company has set a goal of expanding its domestic operations by 20% per year for the next five years.

“As promised, Soft-Tex has delivered and now continues to expand upon its commitment to growing its domestic footprint,” said Mark Smiderle, Soft-Tex principal. “These efforts will continue to improve Soft-Tex’s, and in turn, our partners’ overall service quality, speed, and costs, which we recognize is critical to driving continued growth.”

Dallas-based Corsicana added a new boxed bedding factory in La Porte, Ind., last year.

Dallas-based Corsicana Mattress Co. planted a new boxed bedding factory in La Porte, Ind., last year, investing more than $8.6 million in the 165,000-square-foot factory. The company has added boxed beds to each of its five brands to give retailers the ability to capture online consumers.

The factory has the capacity to produce 1,500 mattresses a day, which will allow the company to ramp up to same-day shipping.

When it opens in April, Bedding Industries of America’s new factory, showroom and distribution center in Rialto, Calif., will serve retailers in California, Nevada and part of Arizona.

Bedding Industries of America is readying for an April 1 opening of its 80,000-square-foot factory, showroom and distribution center in Rialto, Calif., to serve retailers in California, Nevada and part of Arizona.

“With the industry landscape changing and demand for our products so strong, we saw the need for a facility in Southern California to better serve our clients,” said Stuart Carlitz, president and CEO of Eclipse International. “This year, for the first time in our industry’s history, demand outpaced capacity, and we expect strong demand to continue well into 2021 and beyond.”

U.S. Bedding in Fall River, Mass., is relocating its factory to a more efficient 136,000-square-foot space. A licensee of Spring Air International, the company has secured a former Sam’s Club warehouse and is installing new manufacturing equipment.

“In just two short years, we have expanded the Spring Air line in the region and are very excited about the additional opportunities for growth the new facility provides us,” said David Nguyen, president of U.S. Bedding. “The enhancements in efficiency, additional production capabilities and logistic advantages will help us keep up with the increased industry demand we are experiencing.”