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Mattress packaging: solutions for every logistical and transport need

From vacuum-sealed to rolled: Dolphin Pack technologies to protect, compress, and optimise mattress storage and transport

Mattress packaging is a crucial step in ensuring protection, quality and logistical efficiency. Well-designed packaging helps preserve the product's characteristics, prevent damage during transit, and optimise space in both warehouses and shipping vehicles.

In the mattress and online retail sectors, packaging efficiency directly affects a company's competitiveness. Over the past 20 years, this market has changed significantly: an increasing number of consumers now buy mattresses online, making packaging solutions that facilitate direct-to-consumer delivery and provide a flawless purchasing experience absolutely essential. Mattresses can be bulky, difficult to handle and expensive to transport, which is why selecting the right packaging method is vital to reduce costs, improve logistics and ensure the final customer receives a product in perfect condition.

In this article, we will explore the advantages of mattress packaging and the most effective solutions for their wrapping.


 

Why is proper mattress packaging important?

Mattress packaging is not just about appearance—it has a direct impact on protection, preservation and logistics. Inadequate packaging can compromise product quality and integrity. Moreover, inefficient packaging can complicate handling and storage, increasing logistical costs due to the excessive volume occupied.

For companies in the mattress sector, a damaged or difficult-to-handle product can lead to higher return rates, customer dissatisfaction and loss of competitiveness. That’s why it is essential to adopt technological solutions that ensure protection against external elements, optimise volume and facilitate handling throughout the entire supply chain, from production to final delivery.

flat, vacuum and rolled mattress packaging

In this context, automating packaging through advanced mattress packing machines offers a significant competitive advantage: it ensures uniform packaging quality, reduces human error and increases the efficiency of the entire production process.
 

Mattress packaging: different solutions for different needs

Mattresses can be packaged using various technologies, selected according to product type, logistics, and distribution needs. The main solutions include flat packing, vacuum compression packing and rolled packaging.

 

Flat mattress packaging

 

Flat packing is the most basic and traditional method, ideal for rigid mattresses or products that, due to their nature or market positioning, cannot be compressed or rolled. This solution preserves the mattress structure and is often used in B2B contexts or when mattresses are delivered directly after production, without the need to optimise transport space.

For this need, Dolphin Pack offers the Mistral 3B MT mattress packing line, a highly reliable solution that quickly wraps mattresses and toppers in a single process, ensuring professional packaging tailored precisely to the product’s dimensions and characteristics.


 

packing mattresses flat

 

 

Vacuum compression mattress packaging

vacuum compression packaging of mattresses

 

In everyday language, the term “vacuum-sealed” is often associated with compressed and rolled mattresses. However, at Dolphin Pack, vacuum packaging refers to flat compression using a special barrier film, such as PAPE (a combination of polyethylene and nylon), designed to provide long-lasting airtight sealing and maintain mattress compression over time.

To achieve these results, Dolphin Pack has developed a double sealing bar system that creates a high-seal double weld on the product, preventing air ingress and protecting it from moisture and dust. This system is integrated in the Pelér line for flat vacuum compression of polyurethane blocks and is also available in the Mistral 3B MT + Press line, an automatic solution dedicated to the mattress sector.

Additionally, for companies seeking a compact and efficient vacuum packaging option, Dolphin Pack offers the Zephyre SV, a semi-automatic line that, when used with pre-formed barrier film bags, enables permanent vacuum compression of pocket spring, conventional polyurethane and visco/memory foam mattresses, thanks to its patented sealing bar system and press.
 

 

 

Rolled mattress packaging

 

When the goal is to maximise logistical efficiency and drastically reduce volume, rolled mattress packaging becomes the strategic choice. Due to the compressibility of materials such as foam, the overall bulk is significantly reduced. This greatly facilitates storage and transport operations, making it especially advantageous for e-commerce and B2C deliveries. Logistically, a rolled mattress is easier to handle, simplifying operations and enhancing the customer’s purchase experience.

Dolphin Pack’s most suitable solution for this process is the Etesian line, designed to compress and roll mattresses without compromising their quality. The Etesian line is available in several models and can be configured according to the customer's specific production requirements, thus offering maximum operational flexibility. 

packing rolled up mattresses

This advanced solution allows mattresses and toppers to be packaged, compressed, folded and rolled in a single step, optimising time and resources. Thanks to its ability to handle high production volumes, Etesian is ideal for companies requiring high efficiency without sacrificing finished product quality.

Furthermore, to meet the growing demand for sustainable solutions and eco-friendly packaging—now a vital requirement for staying competitive in today’s market—the latest addition to the ETESIAN range is the Smart Hybrid version. This compact machine retains all the advanced features of the line, allowing mattresses and toppers to be packaged, compressed, folded and rolled, with one major innovation: the ability to use paper as a packaging material. This solution combines production efficiency with environmental consciousness, perfect for companies aiming to align performance with sustainability.

What’s more, this solution can reduce mattress volume by up to 80%, drastically cutting transport costs, optimising warehouse space and reducing CO₂ emissions from shipping, all without compromising the product’s structural qualities.


 

Find the ideal mattress packaging solution!

Thanks to the flexibility and modularity of Dolphin Pack’s technologies, every company can adopt the system best suited to their production and distribution needs, ensuring safe, efficient mattress packaging that is fully integrated into the logistics chain.

Whether you need to pack mattresses flat, vacuum-sealed, or rolled, Dolphin Pack has the right technology to optimise your production process.

Contact us for a tailored consultation and discover the most suitable machine for your packaging needs!