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Factory Location:
4648 Old Hickory Blvd
Old Hickory, TN 37138
Hours of Operation:
9:00 AM - 4:30 PM, Monday - Friday
Closed:
Saturday & Sunday
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Our Mattress Manufacturing Process
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Here at AMC we own all of our factory debt free! We use our own machinery such as an incredibly durable Gribetz Quilter, Galkin Tape Edge Machine, James Cash Panel Cutter, BK6 Spring Unbaler, Juki Serger, Union Special Straight Tape Sewer, Consew Long Arm Quilt Repair Machine, and other industry top-of-the-line equipment to make your product last for years to come.
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Gribetz Quilter |
BK6 Spring Unbaler
James Cash Panel Cutter
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Juki Serger
Consew Quilt Repair Machine
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At AMC, we don't build a junk mattress to leave you with body impressions a year later. We specialize in comparing our products to those readily available in the market. We compare our foams, and always give you a higher density. We apply scientific industry standards to measuring our components, and ensure you the best deal. At AMC, you'll always get an oven tempered spring unit, which requires the use of a spring unbaling machine just to get at it! These spring units are compressed after tempering, inspected prior to shipment, and inspected again while un-baling. If anything is wrong with this type of spring unit, it will simply explode on expansion. For this reason, we guarantee you a good innerspring.
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The next promise we make to our consumers is the fact that we never use cotton batting as an insulator pad inside our mattresses. Cotton is a very cheap insulator product, and absorbs moisture. This is why we wear t-shirts generally made from cotton. T-shirts are fine, because you can wash and dry a garment, but you can't do that with a mattress. For this reason, AMC always uses synthetic insulator pads. They don't look like much, but they don't lump and clump and they won't hold moisture. This is a key to longevity when building a mattress.
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Synthetic Insulator Pads
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As we apply both the insulator pad and the flange attached to the top panel of your mattress, we use what's referred to as "C-Ringer's" to lock your top to the side of the coil unit on the inside of the mattress. This keeps your materials from slipping, lumping or clumping. Many manufacturers skip this, and simply close the mattress. We always c-ring the flange on your product!
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Tworon Flame Resistant Thread
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In the factory, we carefully quilt the top panel in a variety of multineedle quilting patterns. Smaller for firmer, and more open for softer. As we do this, we carefully select what foam layers, innerpanel, and top fibers to put in your top panel. We quilt this top panel using only the best thread and tape edging in the industry, with Kevlar fire resistancy using Tworon thread, not some cheap Chinese thread made from ceramic that stresses or breaks every time you sit or roll over in the mattress.
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After slitting your border, and cutting your top panel, we go to the build up table and bond the foam layers, and apply the edge support system of choice. We use both high density foam encasement, and double spring edge supports for your comfort when sleeping on the edge or for example, putting your shoes on.
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All of American Mattress Company's products utilize kiln dried hard wood in the platforms for either a boxspring or foundation. Kiln dried hard wood is much better as it won't creak and crackle, and it also doesn't expand or contract from the barometric pressure around your house changing. Our heavier grade products utilize the latest technology in boxsprings - torsion bars. Torsion bars hold much more weight than traditional round springs. They react more when more weight is applied, and vice-versa.
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Kiln Dried Wood Fabrication
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Galkin Tape Edge Machine
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After completing your foundation, we move on to the tape edge station and close your mattress and any tape edging on your boxspring or foundation. This is a highly-trained, skilled craftsman that works this station. He must have a keen eye to keeping both your panel straight and the border straight, all while simultaneously closing with fire resistant tape edging. This process is done completely by hand.
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While all this is going on, we also engage a variety of other machines such as a commercial grade "serger" which attaches the "flange" to the underside of your top panel, all while hemming the border with a zig zag lock-stitch to ensure no unraveling at your edges. Our Union Special Box Tape machine ensures a strong back seam underneath your foundation cover, sometimes even two of them. All pillowtops with gussets endure this process, so you have no "crowning" over at the edge of your pillowtop. You can literally pull one inside out, and it won't separate.
After closing your mattress, it then goes to quality approval. We check all facets of your product, and review all Underwriters Laboratory requirements to "batch" your product into the books for inspection.
Mattress Closing Process |
Hand Made Products! |
We always use a law label, and this is very important, as the barcode shows who built your mattress, what parts, and what dates. It also has a date of production on it, and this is how you verify you're getting a new mattress. That's what all the mattress police jokes are about. Yes, you can tear it off, but keep it in a plastic bag under the mattress, as this barcode actually is the warranty on the product. We do recommend you always leave the labels and tags on the product for warranty purposes.
Example Mattress Anatomy of Law Label (PDF Format)
At American Mattress Company, we're certified members of the International Sleep Products Association. We subject ourselves to tremendous scrutiny by submitting valuable data that compares products, prices, wages, and a variety of other surveys.
We always sell only Certificate of Compliance products. These products have been tested according to a wide variety of testing procedures, including the battering ram test (Cornell test), rollator test, and ILD (Indention Load Deflection) testing. All products are Flame Tested a minimum of four times to receive certification. All foams have had "core testing" done to ensure their density and ILD rating. As a result of this process, all of our products carry the coveted Underwriters Laboratory Quality and Durability Certification. We also go to great lengths to ensure compliance with all government regulations such as 16 CFR 33, and a variety of other compliance regulations for the industry.
ILD Foam Scale
ILD Foam Testing Core |
Cornell Durability Testing
Rollator Testing |
No matter what your shape or size, we guarantee to give you a bed that's appropriate for you. We go through turns of the coil, gauge of wire, weight of the coil unit, type of edge support, amounts of fiber, types and densities of foam, and even the thread count to the cover. We carefully gauge your reaction to these components to make sure your mattress is as comfortable as possible for as long as possible, and we always guarantee the lowest price.
Don't see what you need? Call us - if we don't have it - we'll MAKE IT!
Whatever it Takes!
Sincerely,
Darrell Lange - Owner
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