How bed-in-a-box mattresses like Casper and Leesa are packed

See How Bed-in-a-Box Mattresses are Packed in Factories

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One of the best things about the revolutionary bed-in-a-box industry is that most customers no longer have to struggle to get a full-sized mattress through the doorway, past narrow hallways and up the stairs.

Online mattresses today come in a compact box that’s smaller than the box your fridge came in. Getting it inside is a breeze.

Setting up the mattress is just as easy. See my blog post on how to set up a bed-in-a-box in a box mattress in less than 15 minutes.

But have you ever wondered how they manage to get such a big mattress to fit into such a small box? Does it damage the mattress? Can all types mattresses be compressed into a box or is it only some?

I’ll answer all those questions in this post.

How The Mattress Gets Into the Box

This is a video of a Dromma Bed memory foam mattress getting packed into a box using a large automated machine.

Most bed-in-a-box mattresses are packed using the same process.

The first step is compressing the mattress into less than half its thickness using a powerful hydraulic press. This makes folding and rolling it up much easier.

The machine then folds the mattress in half and rolls it up into a cylinder. All that’s left now is to pack the rolled up mattress into a box.

But doesn’t this damage the mattress?

Not at all. Mattress foams, especially memory foam, are incredibly resilient. They can be pressed down and regain their shape many times over.

Memory Foam is able to regain its form after depressing it

If they did not have this ability, your mattress would only last a few months before it sags hopelessly out of shape.

Every morning when you wake up, the foam goes back to its original flat shape. Of course it can only recover so many times.

That’s why mattresses have lifespans of around 10 years (longer for innerspring mattresses).

When you unbox the new mattress and unroll it over your bed, it immediately begins to expand to its normal height. This takes a while.

You can sleep on the mattress after an hour or so but it takes around a couple of days for the mattress to regain its full size.

The only concern of shipping the mattresses this way is off-gassing. These mattresses are usually packed into a tight box immediately after they are manufactured. That ‘fresh foam’ smell doesn’t get a chance to dissipate.

That’s why most bed-in-a-box mattresses tend to have slightly more off-gassing than other mattresses though it fades away in a few days.

But rest assured that compressing it does not cause any permanent deterioration or reduce its lifespan…unless it’s a spring mattress.

Can Innerspring Mattresses be Compressed?

Usually, no. Innerspring mattresses are often delivered as they are with just protective packaging around them.

This is because trying to compress the mattress would warp and bend the innersprings, causing permanent damage. Unlike memory or latex foam, pocketed coils can’t bounce back after being bent.

So if you are planning to buy an innerspring mattress, make sure it can get through the doorway and up the stairs.

If you are afraid that it will not fit, check whether the company offers the option of split mattresses. This is usually only possible with Queen and King sizes. You may have to pay extra for a split mattress.

I’d also recommend paying for white glove delivery. The mattress will be delivered and set up for you. Trying to carry a heavy spring mattress to the bedroom is a lot of work even for two people.

What are The Advantages of Compressing a Mattress into a Box?

Idle Mattress corner shot
A boxed mattress is easier and cheaper to ship.

You might be wondering what’s the point to all this. Can’t they just delivery the mattress the good old way?

It’s all about logistics and saving money.

Compressed mattresses take less space and are easier and faster to ship to customers.

Companies also spend less on shipping boxed mattresses and the savings are passed down to customers in form of free delivery and cheaper mattress prices.

It also makes things so much easier for customers. You don’t have to lug a heavy full-sized mattress up the stairs. Just carry the box inside and unbox the mattress right on the bed.

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Select a list >MattressesToppers & PadsCooling/HeatingPillowsSheets
Touch a tab above to reveal my top picks for that category.
Of the 60+ beds I've reviewed, these are my current favorites:
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Mattress toppers & pads are a great way to cool your bed and extend its life.
Topper SizeMaterialFirmnessWarr.
LINENSPA 2 Inch Gel Infused Memory Foam Mattress Topper, Twin
Best Value2"Gel memory foamMedium3 years
Best Comfort3"Memory foamMedium-firm5 years
MyPillow Three-inch Mattress Bed Topper (Twin)
Best pressure point relief3"FoamMedium-firm10 years
LUCID 2-Inch Ventilated Gel Infused Memory Foam Mattress Topper - Full
Best cooling2"Gel memory foamSoft3 years
Milemont Mattress Topper Twin, 2-Inch Cool Swirl Gel Mattress Topper for Twin Size Bed, Blue
Best for back pain2"Gel memory foamMedium10 years
Pure Green
Pure Green 100% Natural Latex Mattress Topper - Firm - 2 Inch - Queen Size
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Sleep Innovations
Sleep Innovations 4-inch Dual Layer Gel Memory Foam Enhanced Support, King, Made in the US Mattress Topper
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Sleep Number DUAL TEMP
Sleep Number DUAL TEMP
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Tempur-Pedic TEMPUR Supreme 3-Inch Mattress Topper Medium Firm, Full, White
Best memory foam3"Memory foamMedium-firm10 years
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Bed cooling/heating systems have come a long way – especially the BedJet, my favorite.
SystemTypeBest For...Temp. RangeControl
BedJet V3
BedJet V3
Air cooledBEST OVERALL (esp. for night sweats)66°F-104°FWireless remote control/smartphone app
ChiliPad Cube 3.0
Chili Technology chiliPAD Cube 3.0 - ME and WE Zones - Cooling and Heating Mattress Pad - Individual Temperature Control, Great Sleep Enhancement, Wireless Remote Integration (Queen (80" L x 60" W))
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Ooler Sleep System
Ooler Sleep System
Water cooledBest temperature control55°F-115°FSmartphone app via Bluetooth
The Pod by Eight Sleep
The Pod by Eight Sleep
Water cooledBest smart cooling system55°F-115°FSmartphone app/smart voice assistant
Mattress Cooler "Classic"
2020 Mattress Cooler "Classic" Chilled Water Sleep Cooling System (Now with a Spare "27x63" Cooling Pad)
Water cooledBest budget cooling systemN/AWireless remote control
SleepNumber Dual-Temp v3
SleepNumber Dual-Temp v3
Air cooledN/ARemote control
bFan Cooling System
bFan Cooling System
FanBest bed fanN/AWired remote control
Brookstone bed fan
Brookstone Bed Fan with Wireless Remote
FanN/AWireless remote control
These pillows excel at relieving neck and shoulder pain:
PillowWhy I Like It
PlushBeds Shredded Natural Latex Pillow
Best Cooling Mattress Pads

best shredded latex pillow for side sleepers
Coop Home Goods Memory Foam
Coop Home Goods - Premium Adjustable Loft Pillow - Hypoallergenic Cross-Cut Memory Foam Fill - Lulltra Washable Cover from Bamboo Derived Rayon - CertiPUR-US/GREENGUARD Gold Certified - Queen
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MARNUR Contour Pillow
MARNUR Cervical Memory Foam Pillow Orthopedic Contour Pillows for Neck Pain Ergonomic Pillow with RoHS Certification and Pillowcase Covers, White(23.5×14.5×5.5 Inch)
perfect spine support using a groove down the middle
SleepRightSplintek Side
SleepRight Splintek Side Sleeping Pillow Memory Foam Pillow – Best Pillow for Sleeping On Your Side – 24" x 5" Standard Size
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Xtreme Comforts Adjustable Pillow
Xtreme Comforts Hypoallergenic, Adjustable Thickness, Kool-Flow Micro Vented Bamboo Shredded Memory Foam Bed Pillow for Sleeping, Back, Stomach & Side Sleepers, Queen Size, Made in USA
thinner and softer than most, so your head will not bend back
UTTU Sandwich Pillow
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Mediflow Water Pillow
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Cradle Me Cervical Pillow
Cradle Me Cervical Pillow - Orthopedic Contour Memory Foam Pillow for Back and Side Sleepers with Neck and Spine Support - Helps Reduce Back and Neck Pain
best overall design with lots of position choices
KaUa Neck Roll
K Ka Ua Neck Roll Pillow Cervical Bolster with Bamboo Cover – Memory Foam Spine Lumbar Traction Spondylosis Support 4” Diameter x 17 “Length (4 Inch)
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J-Pillow Travel Pillow
J-Pillow Chin Supporting Travel Pillow - 2020 Version - British Invention of The Year Winner - Supports Your Head, Neck & Chin (Blue)
added chin support prevents your head from falling forward.
EPABO Contour Memory Foam Pillow
EPABO Contour Memory Foam Pillow Orthopedic Sleeping Pillows, Ergonomic Cervical Pillow for Neck Pain - for Side Sleepers, Back and Stomach Sleepers, Free Pillowcase Included ( Firm & Queen)
Designed to support and cushion you neck and shoulders
J-Pillow Travel Pillow
AVOCADO GREEN PILLOW-Loveable non-toxic pillow has an adjustable fill, made from GOLS organic certified latex and GOTS organic certified kapok.
An all-natural, organic and vegan pillow with an adjustable loft to suit all sleeping positions
These are my favorite luxury sheet sets sold online:
Best Luxury SheetsIncludesSizesColours
Fitted sheet + two pillowcasesTwin to Cal KingSand, Slate, White, Light Grey, Blue
Brooklinen Luxe Core Sheet Set – Includes 1 Flat Sheet, 1 Fitted Sheet + 2 Pillowcases – 480 Thread Count Sateen Sheet Set – 100 Percent Long-Staple Cotton – Oeko-TEX Certified – Smoke – Twin
One flat sheet, one fitted sheet, and two pillowcases.Twin to Cal KingWhite, Cream, Steel, Smoke, Smoke Stripe
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Boll and Branch
Boll & Branch Luxury Fair Trade Long Staple Organic Cotton Sheet Set - Full, Natural
one fitted sheet, one flat sheet, and two pillowcases.Full, Queen, King, Cal King onlyWhite, Solid Natural, Striped White, Pewter
Best For Specific Needs Soft and Warm: Parachute’s Sateen sheets Most Luxurious: Brooklinen’s Linen sheets Organic Luxury Sheets:  Saatva Lofton Organic sheets Breathable/Cool: Percale sheets from Parachute or Brooklinen

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2 thoughts on “See How Bed-in-a-Box Mattresses are Packed in Factories”

  1. Hi! We’re new to online mattress buying and especially to this ‘bed-in-a-box’ thing. It’s understood that all foam beds can be packed this way, but we cannot believe or accept that this method would not damage the coils of a hybrid! How is it possible to fully compact and ROLL a mattress with steel springs and not damage or at least compromise the structural integrity of those coils?? Something like this would seriously degrade and reduce the lifespan of the bed, which are usually short as it is.
    Please help us to understand, as it seems no one sells beds ‘flat’ any longer. 🙂

    • Great question!

      Yes, we thought the same thing at first. But it’s not a problem. Compressing coil spring mattresses into a box doesn’t harm the mattress at all.

      This is partly because the foam layers insulate the coils from total compression and partly because the kind of steel they use does not permanently deform under packing pressure.


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