[Woman:] The average person sleeps for 1/3 of their life. Based on current life expectancy, that's a total of 25 years of sleep.
[Man:] That's a lot of sweet dreams and face it, a lot of drool.
[Woman:] So why not be as comfortable as you can be with a Springwall mattress
[Woman:] We're heading to Mississauga, Ontario to visit Springwall's 80,000 square foot factory to see how they make their mattress
[Man:] That's right, and this is the directory of manufacturing for Springwall, Brett Leddingham.
[Man:] I'm sure he's going to stop spinning soon.
[Woman:] I wish he would. He's making me dizzy
[Brett:] We work hard all day so you guys can sleep well at night.
[Man:] A hard worker eh? I guess you weren’t laying down on the job. On one of your mattresses. Get it?
[Brett:] [Laughter] Sorry. Ok.
[Woman:] Each Springwall mattress is made to order. Today we'll be following a queen size bed.
[Man:] This here is Norman and he's making a mattress panel.
[Woman:] So what exactly is a panel?
[Norman:] The panel is the top part of your mattress, like the cover.
[Man:] Oh cool, so is this the place where all the magic happens?
[Norman:] I don’t know if it’s magic, but stuff happens
[Woman:] fabric made of polyester & cotton blend and 2 layers of foam are quilted together by this massive sewing machine, which stiches at 1100 revolutions per minute.
[Woman:] And here is Norman's finished product. Ta-daa.
[Norman:] That's it, that's the big show.
[Man:] Mala takes the completed panels and sews the edges together. it looks pretty comfy already, and we're just getting started.
[Woman:] I suddenly have the urge to put on my PJ's.
[Woman:] Now it's on to the making of the vent borders. This feature encourages air flow to keep the mattress nice and cool, and eliminate moisture.
[Man:] This is Norumanie, and she's the lead hand of the sewing department.
[Norumanie:] I'm nervous.
[Woman:] It's alright, it’s just your career as a potential television star that's hanging in the balance.
[Man:] That's right, now say something witty please.
[Norumanie:] We don't let no one lay down on the job.
[Man:] Norumanie's handy work is then transferred in this 45 meter spool over to the cutting department, where a worker measures out 6.5 meters of fabric and cuts it to size.
[Woman:] A tag with the company name is then sewn on the border.
[Man:] And now, it’s time to start building the comfy part of the mattress where the all-important beauty sleep happens. A worker takes a fibre pad and glues 4 foam sides to the edges.
[Woman:] Then it’s off to Karim. A man who knows exactly what kind of mattress-based puns we're after.
[Karim:] This will put a spring in your step.
[Man:] Ah see, there you go.
[Man:] The springs of the mattress arrive wrapped up like a giant jelly roll.
[Brett:] It's a zoned coil system. That helps support all the heavier pressure points during your sleep. So when you’re sleeping with your partner, and there's movement, you don't feel it.
[Man:] Ya that's good because I really need my 8 hours of undisturbed sleep. You know, in the zone, otherwise I'm very cranky.
[Woman:] Karim places another piece of foam on the top and then glues it all together.
[Woman:] Now that we have the panel, the borers, the foam and the coils, it’s time to assemble this bad boy.
[Man:] That's right. This worker uses a staple gun to attach the border and the bottom of the mattress, which is also called the Decking.
[Woman:] Both the decking and the borders are sewn in place.
[Man:] A final layer of specially ordered Aquagel foam is added. Aquagel acts as a memory foam and actually contours to your body while regulating your body temperature. Cool.
[Man:] Norma's quilted panel is placed on top of the Aquagel, and then it's time to close up the mattress. The 6 layers of foam, coils and springs need to be tailored.
[Brett:] The final tailoring that's put on a mattress is hands down the most difficult position in the factory.
[Man:] And here's the man in charge of the most difficult job at Springwall: meet Chris. So what do you do?
[Chris:] Blah blah blah blah blah
[Woman:] One more try Chris:
[Chris:] We do the tailoring of the mat, and, that's all I got.
[Man:] Eh well, that's a little better. Chris is responsible for sewing the mattress up with the quilted panel. Since this is what the customer sees, a steady hand is required and no mistakes can be made.
[Chirs:] I make the bed look sexy.
[Woman:] once Chris is finished loading up the mattress with sex appeal, it's sent down the line where it is wrapped in this machine.
[Norman/Karim:] That's a wrap! You mean a nap.
[Woman:] Oh you guys.
[Man:] That's not a nap. That's a nap.
[Woman:] So is there a company mandated nap time at Springwall?
[Brett:] I'm not at liberty to say.
[Woman:] Well after he's got his power nap in, the mattress can be shipped off to its brand new owner, where it can make itself at home in the bedroom, ready to lull a tired body to sleep.
[Man:] Shhh, let's go, we don’t want to wake her up.
[Woman:] Ok byyye!