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The Industrial Estate NOT The Retail Park

ALL DIVANS AND MATTRESSES MANUFACTURED ON THE PREMISES. BUY DIRECT FROM OUR IPSWICH FACTORY

About Us

Deriving from one of Ipswich’s oldest established family businesses (Barnes of Ipswich Ltd ) The Bed Factory has grown in it’s own right carrying on the ethos of the original company. This comprises of total customer service and the constant offering of quality products at sensible prices 12 months of the year. The company prides itself on not entering the so called 50% regime where prices are totally without foundation, also the majority of cases supply and deliver exactly the same product at a cheaper price than the so called superstore half price offering. The service element comes from committing to large stocks even buying in container loads for the best price but more importantly when you purchase a product it will usually be delivered from stock on the day you were promised at time of ordering.

Our showrooms always have over 50 beds and mattresses on show offering a wide selection of sleep products. Our range comprises of Metal Frames, Pine Frames, Medical Beds, Headboards and our own produced Divan Sets  and Mattresses. We also specialist in more unusual beds like Round Beds and as such in sizes up to 7’0” by 7’6” and special sizes for antique frames etc. In fact if it is possible to make then we can manufacture it  on our premises to your requirements Also in our showroom you will find our associate company Barnes Carpet 1st offering a range of flooring to compliment any home.

200 Showroom
200 Microquilter

Set immediately behind our showroom area is the actual manufacturing facility which during normal production times you are cordially invited to view ( subject to staff availability ). This will give you the chance to actually  see the production processes undertaken and the care with which all our sleep products are produced by craftsmen with more years than they care to mention between them in producing quality sleep products. We are constantly  updating our machinery to ensure our ranges all meet our high standards while giving the customer a specialized service but at a realistic price and in 2008 made our largest investment of over £130.000 pounds in new plant and  equipment to increase our range even further. Shown left is part of that investment a TEC microquilter which produces our Micro range and all our mattress borders to a very high standard.

This is the starting point of either the base or mattress where the rolls of ticking are stored and production pre-planned for the mattress and base departments to have there requirements ready as required by our  very flexible in house system. They cut to various widths ready for our seamstresses to sew up for divan bases. The picture shows materials stitching through a vertical border machine ready for the  mattress making department but this has now been replaced with the Microquilter system above. All ticking is checked for the unlikely event of flaws by our own staff to ensure that your purchase reaches you in perfect condition. Most of our covers are commissioned by our  company from the leading textile mills in Belgium to our own designs and textures with others imported from Italy and beyond.

200 Cuttingroom
Andy 200 x 140

Probably the most interesting from a customers view point is the mattress department as this is the actual part you sleep on. The picture shows an overall view of our mattress making area with the tufting machine in  the foreground. This piece of equipment is used to compress the mattress prior to tufting so as to ensure all materials used in production are held tightly in place. Behind this one of our staff is preparing a  spring unit with its insulator pad in place to prevent spring feel, and the other softer upholstery layers from coming into contact with the spring unit. Further behind is a quilting machine, in essence a giant  sewing machine which can stitch through many layers of upholstery holding them all together. Where mattresses are quilted there is no need for tufting as this is a very similar operation which is to achieve a  bonding between all the upholstery layers.

200 Alanstaper

Once all the preparation work has been completed the final part of mattress assembly is the tape edging. In essence this machine has a angled sewing head which stitches the side of the mattress to the top and bottom  respectfully. This machine is operated from behind so to speak which means that the operator walks backwards while sewing which if you imagine that the circumference of a standard mattress is 7 metres then times  that twice for each side. This means that our operator could walk backwards over half a mile on a busy day but a lot of factors would have to be taken into account for this distance to be achieved.

200 FrameMaking

We purchase all our timber in standard long lengths and cut to the required sizes on our premises. Although this is a slightly more expensive way it does mean that we can check the product more thoroughly and avoid knots etc.  from being in structural or load bearing places. The picture shows one of our staff joining a pre assembled side section to the top rail of the base containing the headboard nuts. This frame will then be left to dry before being  upholstered.

200 Upholstery

The final part of base production is the upholstering of the wooden framework produced above. The material cases are received from the cutting room and then stretched over the divan frame. The upholster then staples this to the  underside of the frame giving the material a taught finish. He would also cover drawer fronts if this was required and then proceed to put a polyproplene cover over the underside of the base to finish of the product.

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