mattresses in boxes in warehouse

5 Surprising Things That Can Happen When a Mattress Is Stuffed Into a Box

by
/ April 29, 2022

Here at Saatva, we don't sell mattresses compressed into boxes. Based on our years of experience in the mattress space, we don't think they offer the best quality for your money. 

After all, any mattress that can be rolled up and stuffed in a box is never going to offer the same long-lasting performance as a premium product delivered intact. If you don’t believe us, just take a look at this video to see what can happen when a mattress is crushed:

Can a mattress that's been flattened down to an inch so it can be folded, rolled, vacuum-sealed, and packed into a small shipping box really give you the comfort and support you need to get a good night's sleep for years to come?

Our experience tells us that it can't. That's why we handcraft all of our mattresses with premium materials that can't be compressed. Watch this video to see how a Saatva mattress gets made:

Over the years, we've cut open countless mattresses in boxes to study how compressing, folding, and rolling can affect the materials inside. Here’s what we’ve learned. 

5 things that can happen to a mattress when it’s stuffed into a box

This is what compressing, folding, and rolling can do to a mattress:

1. It can compromise safety

All mattresses are required by law to have a flame barrier. At Saatva, we use natural thistle, which is a product derived from wood pulp, as well as organic New Zealand wool. But many compressed foam mattresses use a fiberglass sock underneath the outer cover as the flame retardant

When you flatten a mattress, fold it in half, and roll it through a compression machine, this can damage the sock and reduce the safety of the product. The fiberglass shards could even penetrate through the cover and escape into the room.

There's been more than one class-action lawsuit in recent years against brands that use fiberglass socks in their mattresses. 

The issue in these cases is that while the mattresses usually have a removable outer mattress cover, consumers aren't warned that removing the outer cover exposes the inner layer of fiberglass. 

Once the cover is removed, fiberglass particles can be released into your home, where they can negatively impact your health. The potential risks of exposure to fiberglass shards include itchy skin, eye injuries, upper respiratory infections, and lung scarring. 

2. It can break the foam

Foam mattresses usually contain base support layers made of polyurethane foam and upper comfort layers made of memory foam. The denser the foams, the more durable and supportive the mattress. Bed in a box companies use less dense foams so the mattresses can be flattened and crammed into a shipping box. 

The memory foam comfort layer in one leading bed in a box is 3.5-lb density, for example, while Saatva's Loom & Leaf mattress has two memory foam comfort layers—one made of 5-lb viscoelastic memory foam and the other made of 4-lb convoluted memory foam infused with cooling gel. 

Foam is like a sponge, and it has tiny cells that can break when you compress them. Not all of the cells will be broken during compression, but enough of the cells will break that the lifespan, and support, offered by the mattress will be reduced. 

3. It can destroy the coils

Some boxed mattresses contain a layer of innerspring coils. Typically, these coils are made from thinner wire than the coils in traditional mattresses so they can be more easily compressed, folded, and rolled. 

The coils in one leading bed in a box are 15-gauge, for example, while the two layers of coils in Saatva’s innerspring mattress are 13-gauge and 14.5-gauge (the lower the gauge, the thicker and more durable the coil). 

When the mattress is folded and roll packed, two to three rows of coils in the center of the mattress, where it folds at the crease, are usually destroyed. This can reduce the support and lifespan of the mattress. 

4. It can compromise the back support

The center third of a mattress is the most important for lumbar support because it's where most of your body weight lies. 

Folding the mattress can compromise the lumbar support in the center third of the mattress, leaving you with less support for your back. As a result, you could wake up with aches and pains.  

5. It can reduce the lifespan of a mattress

While the average lifespan of a mattress is seven to 10 years, most mattresses in a box will have a reduced lifespan because of what happens to the materials inside when they're compressed, folded, and rolled. That means you'll have to spend money sooner to replace your mattress. And some mattresses in a box cost well over $1,000! 

Plus, sleeping on a mattress that's past its prime can come with its own set of issues—think aches and pains, being able to feel your partner move around in bed, and just not being able to get comfortable overall. 

How Saatva differs from mattress in a box brands

Saatva mattresses never come stuffed in a box—instead, they're handcrafted and made to order, then delivered and set up in the room of your choice. When you purchase a Saatva mattress, whether online or at one of our Viewing Rooms, you get a factory-fresh, American-made mattress that's been manufactured just for you.   

Our mattresses all contain high-quality materials that could never be compressed. And our flame retardants are made from natural materials, like plant-based thistle and wool, that are free from harmful chemicals. 

White glove delivery is also standard with every Saatva order. We deliver and set up your mattress so you don't have to worry about lugging a heavy box up to your bedroom. 

We give you plenty of time to enjoy any Saatva mattress in the comfort of your home before deciding if it’s right for you. All of our mattresses come backed by an industry-leading warranty because we stand behind the quality of our products. 

Check out our selection of premium mattresses and take our mattress quiz to find your perfect match. At Saatva, we believe you deserve better than a bed stuffed into a box. 

From now through Memorial Day, take up to $450 off your purchase of a Saatva mattress in our best-ever Memorial Day Sale. Check out our current sale offerings for more details.

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