Once the fabric is quilted the bigger roll is then taken to the cutting table where it is cut down to different mattress sizes. The covers are then taken to the sewing machine where the edges are surged closed to keep the ends of the fabric from fraying.
Finally, the cut pieces are taken to a mattress-closing machine where the pieces are sewn together around the core of the mattress. This is how most, if not all, spring mattresses are made. It is less expensive to make them like this but impossible for you to look inside the mattress or to replace a layer of quilting once it starts to compress and get lumpy.
All our mattress covers are made with a 360 degree zipper. This makes it very easy for you to look inside the cover to verify what you purchased is correct. We have been in the mattress business since 1988 years now and we are still surprised on a regular basis with what we find in some mattresses that are sold in stores.
The zippers will also allow us to inspect your mattress, without having to tear the cover off of it. We can inspect it for warranty reasons or make changes to it if, after using it, you decide that you want to change the firmness or type of foam used.