Quality-Controlled Mattress Surface Fabrics

Automated Cutting and High-Volume Assembly

Quality control is mandatory for manufacturers using expensive, high-speed automation:

• Automated Cutting Tables: Requires highly accurate roll width and zero major defects to prevent machine stops and mis-cuts.
• Global Consistency: Ensures that a final product assembled in Facility A looks and feels identical to one assembled in Facility B.
• Warranty Compliance: The long-term structural quality of the fabric supports the client's mattress warranty claims.

The fabric minimizes scrap, maximizes throughput, and standardizes the final product.

Quality Control and Tolerance Metrics

Core Advantages of Quality Control

• Reduced Scrap Rate: Minimizing defects and dimensional variance leads to higher yield rates in the client's cutting room.
• Manufacturing Reliability: Consistent quality prevents expensive machine stoppages and manual sorting/rejection of flawed material on the production line.
• Shade Consistency: Precise color matching (ΔE control) ensures that different components (e.g., top panel vs. border) match perfectly on the final mattress.
• Predictable Hand-Feel: Consistent GSM and finishing ensure the final product's perceived softness and comfort are repeatable across all batches.

Frequently Asked Questions (FAQ)

• Q: What is an acceptable Delta E (ΔE) value for commercial textiles?
• A: For critical surface fabrics, a ΔE value of ≤1.0 (compared to the approved standard) is generally considered a commercial match, with lower values indicating a closer match that is imperceptible to the human eye.

• Q: How do you track the fabric GSM throughout a long roll?
• A: Continuous weight sensors (beta gauge or radiometric sensors) are used on the finishing line to measure the fabric weight per square meter in real time, ensuring consistency from beginning to end.

• Q: Is a 100% visual inspection truly performed?
• A: Yes. All high-end surface fabrics undergo a 100% visual check by trained inspectors on light tables, often supplemented by automated optical scanning, to identify and mark or remove major flaws before rolling.

SPC Implementation and Control

Control points ensure stability:

• Input Yarn Testing: Verifying yarn denier and strength upon receipt to eliminate raw material variability.
• Knitting/Weaving Tension: Continuous adjustment of machine tension to maintain constant loop size and density (GSM).
• Color Spectrophotometer: Routine measurement of wet and dry fabric samples during dyeing and finishing to guide shade correction in real time.

Production and Data Service

We provide transparent quality data:

• Quality Report Per Lot: Providing a detailed Quality Control (QC) report for every lot number, including actual GSM, width, and final inspection results.
• AQL Compliance: Certifying that the finished roll meets the client's specified Acceptance Quality Limit (AQL) for defect levels.
• Root Cause Analysis (RCA): Partnering with clients to perform RCA on any fabric issue that causes a production stop on their end.