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Factory direct mattress manufacturers in Baton Rouge, LA 04 Jan 2012 21:16 #191

  • phoenix
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Hi Mott,

I am not a fan of airbeds and this article goes into some details about why. Besides many other issues, air is an "on or off" material without any progressive resistance and it has no ability to adjust itself to different sleeping positions. It will always compress as far as the bladder around it will allow. Materials that are more progressively resistant (such as innersprings, polyfoam, or latex) are far better as a support layer because they can naturally adjust themselves to changes in position without having to re-set the firmness of the support layer.

With your height/weight and sleeping positions ... it's quite likely you will need a few inches of softer foam on top for pressure relief on your side. Under this you will need a support layer that can adjust itself to your different sleeping positions to both "help" the comfort layers with side sleeping and to hold up your heavier parts and keep them in alignment in all your sleeping positions. Latex is an ideal material because it can be both soft with some compression and yet gets progressively firmer with deeper compression so it can be used in both the upper comfort layers and the support layers underneath. A good starting point for testing mattresses with your lighter weights and sleeping positions would be about 2-3" of softer latex (in the range of 19 ILD) over firmer latex in the support core (around 28 - 32 ILD). This is a little softer and thinner than a heavier person or a pure side sleeper would normally use. Of course this is just a starting point for testing mattresses and your own experience would "adjust" both the firmness of the layers and the thickness of the comfort layers either up or down. In other words you would likely need a softer layer on top (for pressure relief) and a firmer layer under this (for support) and the "art" of mattress shopping is to find the best combination for both. Some local manufacturers will also make each side of a mattress differently if the needs of 2 people are different enough to warrant it.

There are three and possibly four local factory direct manufacturers that I know about in Baton Rouge and when I talked with them all of them fit the profile of local manufacturers that I like.

www.manta.com/c/mm42vf7/wholesale-mattress-factory They are run by a 72 year "young" guy that carries a wide range of mattresses on his floor and will make just about anything. In his own words ... "he is cheaper and better than any major" and of course this is almost always the case with any factory direct manufacturer. Open, direct, and knowledgeable. Has no website and probably won't until his son takes over the business. EDIT: they now have a website www.wholesalemattressfactory.com/

www.capitalbed.com/ (AKA www.pelicanmattress.com/) Also makes a wide range of mattresses including Dunlop latex and sells mostly wholesale to local outlets but will also sell to anyone who walks through the door (and I think they would be a good place to do just that :)) although of course he won't "undercut" the already good prices of the retail outlets he supplies. Another local manufacturer that is knowledgeable, transparent and has good value.

www.istroumamattressfactory.com/ They are a 75 year old manufacturer that both makes and repairs mattresses. Another "old time" smaller (2 man) manufacturer who has been in business for decades. They manufacture a range of mattresses of using higher quality materials including traditional innerspring/polyfoam, memory foam, and latex hybrids.

A couple of retailers that may also be worth a visit and the manufacturers they carry I would focus on (although you would need to make sure that you are able to find out the specifics of the materials inside any mattress you are considering) are ...

www.aamattressbr.com/ Gonzales, Zachary, LA. Pure Latex Bliss Talalay latex and latex hybrids.

www.beddingplusmattress.com/ Baton Rouge and others in the area. Jamison

www.furnituremarts.com/locations.aspx Baton Rouge and others in the area. Golden, Restonic

There is also a 4th local manufacturer in Lafayette for those who may want to include them in your research and/or take the drive ...

Irvin's Mattress I talked with Scott who is the 3rd generation of family ownership and they are making mattresses of all types including memory foam, talalay latex, and innersprings and use better quality materials and construction methods than you will see in typical chain stores and major brands. I guess Baton Rouge isn't the only local manufacturing happening in Louisiana.
ADMIN NOTE:Retired Website | Archived Footprint: irwinsmattress.com

I personally would spend my time with these as I would seriously doubt if any other outlets in Baton Rouge would have the same combination of knowledge, quality, and value. If I come across others in or near Baton Rouge in the course of my research I'll certainly add to the list in this thread.

Hope this helps

Phoenix
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Re: The Serta iComfort mattress ... what's the buzz 05 Jan 2012 01:34 #192

  • 22bmarsh
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Phoenix,

Thanks for all your help. I called all over today and went to the local places in Sacramento since they're right down the street from where I work. I think I'm going to choose a latex over anything else as they are amazingly comfortable and plush. The next question I have is what do I choose in a latex mattress? I like the talalay mattress but I don't know how much of it I need to use as the core and base. If you could please direct me into the right direction that would be great. Also, to anyone that reads the forums Phoenix does a great job in actually calling the places as of most of the places I went to actually have talked to him and received a call right after I posted my first post. :)

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Re: The Serta iComfort mattress ... what's the buzz 05 Jan 2012 03:44 #193

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Hi 22bmarsh,

A "typical" construction for a latex mattress would be about 2" to 3" of talalay latex over a support system which could be either an innerspring, or about 6" or so of Polyfoam, Dunlop latex or Talalay latex. The reason talalay is a common choice on top is because it has a more consistent feel and can be made in softer versions than Dunlop latex providing better pressure relief. Having said that there are some people who prefer Dunlop and there is no right and wrong here.

Actual testing of a mattress for pressure relief (discovering the thickness and softness of the comfort layers that works best for you) and alignment (the choices between different types and firmnesses of the support system) along with personal preferences is the most accurate way of deciding what is best for each person ... particularly if you have the help of someone who is good at knowing what your feedback points to in terms of the layers that would work best for you. Local manufacturers that make mattresses every day are usually very good at this and have trained their staff very well.

Typically side sleepers would do well to start their testing with a comfort layer in the range of 3-4", back sleepers in the range of 2-3" and more "pure" stomach sleepers in the range of 1-2". Heavier weights generally do better with firmer foams while lighter weights tend to do better with softer foams. That's because the heavier a person is the more they will sink in and foams in general will feel softer to them.

The support material needs to "hold up" your heavier parts to keep your spine in alignment and each of the most common choices (innersprings, polyfoam, and latex) will have a different feel ... even though they can all work well. The higher quality the material and the bigger range of response ... the greater range of sleeping positions and weight ranges a given material can work with. Of course the better materials are also more costly. While there is a range of quality and expense in each type of material or support layer ... generally you can expect polyfoam to be the lowest cost ... a good quality innerspring to be next ... Dunlop and blended Talalay to be next and natural Talalay to be the most expensive material.

This overview along with this page about your sleeping positions and this page about your "statistics" go into more detail.

The easiest way of course is to read enough so you have a general idea (and most of the appropriate information is in the mattresses section of the website) and then take advantage of someone elses' expertise who has been helping "fit" people to a mattress for many years. The more they know and the more willing they are to help you ... the less you have to know or become an "expert" yourself. This is one of the biggest advantages of dealing with a factory direct manufacturer or sleep shop.

So hopefully I haven't overwhelmed you with reading but knowing some of the basics can help an "expert" to help you much more effectively.

Phoenix
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Re: The Serta iComfort mattress ... what's the buzz 05 Jan 2012 16:37 #194

  • soreshoulder717
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How can I find out the ILD of the polyfoam support layer/base of the major brand names making memory foam mattresses?
I know you don't feel the icomfort represents the best value, but it is the line I'm considering currently.(the insight)
I prefer 2.5"-3" on top, no more though.
I prefer the laminated layers and the decent warranty with the Tempur's and iComfort's.(0.75" depression replacement)

If I could get a laminated version from a local manufacturer I would, but there doesn't seem to be any in the Lehigh Valley.(Allentown-Bethlehem PA)

I am a side sleeper(90%) and back(10%).
I am a male, 5'8"-140lbs.
Dislocated C3 and C4.
I will be getting an appropriately sized memory foam pillow as well after choosing my mattress as my current cotton/2.5lb density mem foam @ 1.5" made by me pillow is much too thin after a years use.

I did like the top layer of the gel memory foam, although I do not have an issue with sleeping warm on memory foam like some.

The latex I've tried was much too springy for my personal sleeping taste. Although that was only the Sleep Options line with China pouring.

TIA!!

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Re: The Serta iComfort mattress ... what's the buzz 06 Jan 2012 02:25 #195

I also put a deposit down on an icomfort bed tonight but am second guessing the purchase now that I have read your posts. I have been having significant problems sleeping for quite some time now. Tossing and turning all night long, waking up with headaches, pain in my neck and sore elbows from trying to prop up my pillow under my head. I went to the mattress shop tonight thinking I needed a new pillow but it would seem that my mattress is too firm for me and that is more likely the problem. I live in Alberta, Canada so I don't have as many options but I have been doing some investigating online and I was wondering if you could give me your opinion on a couple of mattresses. I am 5'8" and weigh 135 lbs, my husband is 6'3" and 215. He has also had some lower back problems off and on over the past few years. We also have a king size bed.
FYI The icomfort bed would cost us $1700 and maybe a little less since I know someone who works at the store.

en.memoryfoamcomfort.ca/ I was thinking the cumulus model

www.novosbed.com/

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Re: The Serta iComfort mattress ... what's the buzz 06 Jan 2012 03:15 #196

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I know I am new here, but from what I have gathered the issue with the iComfort lineup is the foundation...NOT the mattress.
The foundation is poorly constructed with weak material and large gaps which could easily be the cause of the premature sagging. I would advise adding a 1/4"-1/2" piece of mdf wood or buying a platform bed instead, with just the iComfort mattress.

I am deciding between an iComfort Insight on a platform or a Tempur-Cloud on either a platform or Tempurpedic's foundation and metal frame. I have been told by the significant other that I have 24hrs to go, haha.

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Re: The Serta iComfort mattress ... what's the buzz 06 Jan 2012 06:14 #197

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Hi Soreshoulder,

IMO ... the real issue with the iComfort is not the foundation (that's easy to "fix" with a different choice) but with the value of the mattresses they and all other major brands are selling to consumers. None of the major brands would be in business for very long if they began to disclose the quality and accurate specs of the materials that they were using in every layer of their mattress and consumers as a whole both knew about and were able to make meaningful comparisons with the many other options that are available from smaller manufacturers across the country.

In your first post you asked ...

How can I find out the ILD of the polyfoam support layer/base of the major brand names making memory foam mattresses?


Unfortunately in most cases you can't. Not only that but in many cases they won't even tell you even more important information such as the density of the foams they use in each layer (which directly relates to quality and durability while ILD relates to softness/firmness and any quality of foam can be made softer and firmer).

If they did disclose the information that is really needed to determine the value and quality of any mattress and what its weak link might be (the part that wears out the fastest) ... they just wouldn't be able to compete with the smaller manufacturers who sell much higher quality mattresses at lower prices and do business based on local reputation and word of mouth rather than advertising stories ... most of which are misleading at best. The irony is that they have access to the same suppliers and materials as the major brands ... they just use higher quality, better construction methods, and sell them at lower prices all year long without any need to negotiate or haggle to get their best price.

There is no other important product that I know of (including cars) where consumers are willing to pay such a large amount on such a blind purchase with so little even basic knowledge and make their purchase based on advertising stories alone.

In the case of the iComfort insight ... you basically have a mattress with 2 3/4 inches of a 4 lb gel memory foam with particles of gel impregnated inside it which are not a part of the memory foam polymer structure (meaning the risk is good that like all particulate additives it may break down the structure of the base memory foam faster) and this is over a support foam that is 1.5 lbs which is lower quality and normally found in less expensive mattresses. For many it may feel great in the showroom ... but so will many other mattresses and do you really know how long an unknown foam like this will last? Is a very basic memory foam mattress like this really worth what you are paying for it? Have you compared it to other memory foam mattresses that use either the same or better quality materials? Most people that go into a chain store have no reference point with which to tell whether what they are being told about the "benefits" of gel memory foam are true or what the claims are based on. What they are being told is all about perception, differentiation, and profit margin.

I have to admit that Serta has done a great job of marketing this mattress and raising awareness about gel materials in general (which have been in the market for some time) and this is clearly their strong point. They really did hit a home run with their marketing but unfortunately consumers are the "other team". Many other manufacturers including many smaller manufacturers across the country are now also coming out with different versions of gel materials and combinations (including various methods of including it in memory foam) and some of these are almost certainly better than the type of gel application used by Serta. They will also likely sell for a lower price ... but consumers in their advertising induced confusion will probably continue buying a lower quality mattress at a higher price just because the major retailers carry them and like the profit margin they provide.

Almost all high quality memory foam mattresses have a .75 warranty but even this is mostly meaningless because long after a memory foam or even polyfoam is too soft to sleep on it still won't usually have an impression deep enough to be covered by a warranty. Warranties are primarily a sales tool used as a closing technique and/or to alter consumer perceptions of quality rather than a legitimate protection against the most common failures of most mattresses.

If I could get a laminated version from a local manufacturer I would, but there doesn't seem to be any in the Lehigh Valley.(Allentown-Bethlehem PA)


The closest factory direct manufacturers along with some of the retail options and possibilities in the area that I would consider (assuming they are willing and able to provide you with the details of what is in their mattresses) are listed in post #6 here .

It may well be worth a few calls to see what they offer that may "compete" with the iComfort in terms of value and your own comfort.

Overall though if you do decide to go with memory foam or the iComfort you are wise to only consider relatively thinner layers of memory foam because of your back issues. Memory foam is a non supportive material (which is why it's never used in the support layers) and thicker layers can aggravate back issues caused by poor alignment in many cases. It may also be worth testing other latex mattresses at these local manufacturers just to make sure how you feel about it mainly because Sleep Options isn't really what I would call a latex mattress (it has some Dunlop layers).

There are always online options if your local choices are more limited but at least you have a couple of options for comparison that are within a reasonable driving distance or at least worth a phone call before you "pull the trigger" in the next 24 hours or so :).

Phoenix
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Re: The Serta iComfort mattress ... what's the buzz 06 Jan 2012 06:46 #198

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Hi Shari,

The cumulus mattress uses very high quality materials (Aerus 5 lb memory foam is one of the best memory foams IMO and is also one of the most breathable memory foams made because of the VPF process that is used by FXI which manufactures it). They also use very high quality polyfoam underneath it (higher quality than most mattresses in this price range). Overall it is a very good mattress.

I would be a little hesitant in buying a mattress online though ... particularly with some of the issues you are having ... mainly because even the best mattress may not provide what you need in terms of pressure relief, alignment, or preferences. Testing a mattress before you buy it or testing a similar mattress with a similar construction is the only way to really know for certain how well it may work for you.

Novosbed uses Chinese memory foam and while it has what would normally be considered to be a higher density (5.2 lbs) ... there are a lot of chinese memory foams that achieve this density using fillers and the foam will not last. It has not been certified for chemicals or offgassing which I would consider to be important especially with Chinese memory foam.

So of these two I would choose the Cumulus but again ... personal testing of a mattress is an important part of the process unless there is a very low cost return and refund available and I would confirm what their policy is here.

If you let me know what city in Alberta you live in I'd be happy to take a look to see if there are any local options I know about. If you happen to live in Calgary there are some excellent options there including two of our manufacturing members .

While it may be true that your current mattress is too firm ... your symptoms could also very well be aggravated by a pillow that isn't suitable for you and/or your sleeping position. What position do each of you normally sleep in?

Phoenix
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Re: The Serta iComfort mattress ... what's the buzz 06 Jan 2012 11:30 #199

I live in Red Deer, which is a little over an hour either way to Calgary or Edmonton. We are both side sleepers. I tend to sleep with 2 pillows. The pillow under my head is a side sleeper latex pillow and then I have a larger pillow I use kind of like a body pillow.
I am a little hesitant to buy a mattress online, for sure, but I am not sure I would know the right mattress for me even if I was lying on it.

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Re: The Serta iComfort mattress ... what's the buzz 06 Jan 2012 12:45 #200

  • CincyBearcat
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Hey Phoenix,
Your posts are extremely helpful which is why I value your opinion. I have done a lot of research and can not make a decision on what to purchase. Right now, my wife and I are leaning towards the iComfort Genius at Mattress Firm for $1699 for the King Mattress only. She is 5'4" 110 lbs. She is a nurse and former gymnist/dancer so has lower back problems. I am 6'4" 200 lbs. I can really sleep on anything but she has been recommended the foam for her back. She really liked the iComfort in the store as well.

As far as money, we are OK with paying extra for comfort and quality but it is hard to get facts from stores. We live in Cincinnati, OH and Mattress Firm is all I can think to go for the foam. Would you recommend the iComfort or Novaform at Costco, or is there something else we should look at?

Thanks in advance!

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