Q Mattress ticking undergoes significant surface abrasion over its 7–10 year lifespan. What specific yarn-interlacing techniques do you use in your Jacquard looms to prevent pilling and snagging from Velcro or rough sheets?
The soft nature and the loop structure of the surface spun yarn make it vulnerable to pilling and snagging. Good quality yarn and correct finishing methods with proper maintenance after purchase are needed to prevent these issues. Even after following these methods, if the correct bed sheet is not used, the problems will remain. No part of the mattress should be exposed and should always be completely covered with the bed sheet. There will be no pilling if filament polyester yarn on the surface. But if the rest of the fabric is also completely polyester, due to static electricity the filler yarns can come out on the surface and the end user will return the mattress. Knit-like woven fabric is an option that is already there in the market. Surface is of filament polyester and there will not be any pilling issues. Because cotton or viscose yarn is there in the fabric, filler yarns will not come out. Since the fabric is not as smooth as a knit, this was not preferred by our customers.
Q Consumers are obsessed with sleeping cool. How are you integrating phase-change materials (PCMs) or cooling yarns (like Polyethylene) directly into the Jacquard weave rather than just as a topical chemical finish?
PCM is infused on the yarn when the fabric is being finished. The yarns could be cotton or polyester or viscose or any other kind. Polyethylene yarn is inherently cool and does not require any special fabric finish.
Q We are moving away from the ‘Quiet Luxury’ of plain white beds toward bold, artisanal patterns. How industry is deciding which patterns will resonate 18 months in advance, given the slow fashion cycle of the mattress industry?
All mattress brands like their mattresses to stand out from the rest. There is also a generational shift, younger generation taking over decision making. This explains why plain designs are being replaced with bolder ones. And with growing competition, they expect to get new designs and concepts from the ticking manufacturers like us, with valuable inputs from their product development team. A lot of work is involved, right from conceptualisation till launch.
Q Most mattresses are covered by protectors and sheets immediately after purchase. How do you justify the cost of premium designs to a manufacturer when the end-user may rarely see the pattern?
The end user is exposed to the bare mattress only, online or offline. He / She will naturally prefer to buy the mattress with premium design than the one with an ordinary design. Bed sheets and protectors are put on the mattress only after the purchase is made.