CSIL Research in EU mattresses

Mattress technology has evolved significantly in the last decade, helped by continuous innovation in the polyurethane (PU) industry and the demand for more sustainable and higher quality materials. PU mattress production is currently worth almost 30-billion dollars annually with polyurethane standing out as the material capable of meeting the most critical consumer requirements.

In the past, mattress brands have not fully utilized color to differentiate their products, but this is changing with a recent survey[1] conducted for Milliken by CSIL, the Centre for Industrial Studies,

finding that colored foam is, indeed, widespread in the European mattress industry. Of the more than 40 companies that took part, 91% used color in their products, with foam mattress specialists using it to a greater extent.

Color in premium and technical PU mattresses

The survey found that most companies used colored PU foam widely in their range and not exclusively for premium products although many mattress suppliers did believe that color is particularly important in the premium segment and for technical products with different comfort and ergonomic zones.

From communication to operations

A key reason for the use of color is the differentiation of mattress layers, and communication with customers, as color is widely recognized by mattress suppliers as a powerful tool to illustrate the structure of multi-layer mattresses. Some suppliers told the survey that retailers very

much appreciate colored, visually attractive mattress cores that enhance product storytelling and look sophisticated.

Companies also use color to differentiate from their competition and to improve their visibility in the market. This is particularly important with consumers increasingly researching and buying products online. Color plays a more relevant role in helping to convey the attributes and value of the mattress.

A second, more practical reason for the use of color emerged in the survey – to visually distinguish PU foam types in the manufacturing phase. This was traditionally the primary function of color in PU foam, helping to facilitate workers’ warehouse operations by enabling them to easily identify foams with specific features.

Sustainability, softness, comfort and cooling

Color is used to call attention to key mattress features. Almost half of the colored foam is intended to convey the message of cooling, breathability and the open cell characteristics of the mattress. Blue is the predominant color used to provide this marketing message. These different features are highlighted by the use of special foams, such as viscoelastic and hypersoft, including the use of PCMs as a coating or dispersed in the top layer. Breathability is third, while color is also used to show if foam has been produced from a renewable resource. The shade used for this is often light green. More than 40% of the companies surveyed considered color in the product design phase whilst 30% considered it during research and development.

Reactint for polyurethane

Milliken’s Reactint^® colorants for polyurethane are leading the trend in colored mattresses and

helping manufacturers utilize the true value of color, without raising concerns around circularity in the PU industry as color does not influence the characteristics of recycled polyol.

To help with color choices, Milliken’s Emerging Confidence ColorDirection 2022 trend report includes prominent trend colors such as: Welcoming Sunshine, a fresh, bright yellow that brings the positive warmth of mornings and the energy of light to your brand; Radiating Richness, a balanced purple created for positive products evoking luxury and self-care; and, Freshening Shoots a bright and vibrant green that represents ecology and sustainability, bringing new life to living.

Milliken has also launched the new, digital Reactint Color Studio – enabling customers to find a Reactint formulation for any Pantone number, with the color wheel, or for any shade in a photo and build a unique color mattress.

In October 2021 Milliken acquired Encapsys, a world leader in microencapsulation, offering brand owners the opportunity to use sustainable coatings based on PCM to improve sleep, thanks to the material’s superior thermal characteristics.

The way ahead

The mattress industry is evolving, driven by mega-trends in globalization, comfort, sustainability, manufacturing, supply chain & e-commerce, and color. In an industry that is continuously evolving and innovating, the use of color is a perfect way to highlight the value of each layer in a mattress. Color can ensure that everyone across the value chain, from the foam producer to the brand owner and the final consumer, fully understands the value and quality behind each foam layer.

CSIL (the Centre for Industrial Studies) interviewed 46 companies, including several of the largest European mattress manufacturers and very large editors focused either in the bricks & mortar, or

e-commerce retail segments.