Manufacture & Production



THE PRODUCTION PROCESS


STEP 1: MAKING THE COVER


THE QUILTING PROCESS

At Bruno, we firmly believe that the first step to the perfect mattress comes down to pairing the highest quality materials with the right skilled partners. With this in mind, we chose to work with a family owned and operated fabric manufacturer located in Saxony.

The first step of the production process involves creating the soft quilted cover top. In order to do this, a filler material is inserted between the upper and lower fabric before the two pieces are sewn together; the result is a high quality quilted upper covering to the mattress which is unbelievably soft to touch.

quilting

SEWING THE COVER

Once the quilted cover top is cut to the right size, the pieces are sewn together and are ready for the next step of the manufacturing process; attaching the zipper.

The concealed zipper running along the inside of the cover is what connects the quilted cover top to the outside cover. The zipper is sewn in by hand and is key to the practicality of the Bruno; making it simple to completely remove and wash the cover.

cover assembly

MADE BY HAND

Our commitment to using real human labour to produce the Bruno Mattress has earned us the Deustches Manufakturen-Siegel (German Manufacturing Certification); one stipulation of this certificate is that at least 50% of the production process be completed by hand in Germany.

This close relationship between real human labour and modern machinery is what allows each Bruno Mattress to be monitored for standards of quality at each stage of the manufacturing process. We think it is this diligence and attention to detail which makes the Bruno Mattress a truly high quality product.

Bruno Label

STEP 2: THE MATTRESS


CUTTING THE SUPPORT FOUNDATION

In order to produce our unique ergonomically-tested design, we pair real human labour with modern machinery, ensuring that the Bruno 7-zone support base is cut with millimeter precision to form the high density foam core

cutting base

ADDING THE LATEX TOP LAYER

The next step for the Bruno Mattress is joining the 7-zone support base with our top layer. The connection of the two materials is carried out by two specialized machines which are operated manually and are closely monitored throughout the process.

One of the key benefits in using latex is that it allows the mattress to adapt to your surrounding conditions, making the Bruno Mattress a perfect surface to sleep on all year round. More on our Materials »

latex layer

STEP 3: FINAL ASSEMBLY


COVERING THE MATTRESS

Now that the 7-zone support base and the natural latex top layer have been joined, a tricot fabric encloses the two materials together before the mattress is wrapped in the hand sewn two piece cover.

mattress

READY FOR DELIVERY

In the final production step, the Bruno Mattress is carefully rolled and vacuum packed. As well as condensing the size of the mattress, the pressure created during this final step helps improve the long-life elasticity of the mattress by “crushing” any millimeter sized air bubbles that may have formed within the foam.

Now, down to a fraction of the original size, the mattress can be tucked neatly into a box and is ready for delivery.

ready for delivery







The Bruno Mattress

Height: 9.5 inches (24 cm)

Please choose a size:
SINGLE
90 x 190 cm
EU SINGLE
90 x 200 cm
DOUBLE
135 x 190 cm
EU DOUBLE
140 x 200 cm
KING
150 x 200 cm
EU KING
160 x 200 cm
SUPER KING
180 x 200 cm



More information on:
90x190 mattress | 90x200 mattress | 135x190 mattress | 140x200 mattress | 150x200 mattress | 160x200 mattress | 180x200 mattress | Mattress Size Guide