Short answer
A roll-pack mattress is compressed, vacuum-rolled and boxed for shipping. At BRN Sleep Products the process cuts shipping volume by up to 75% without affecting quality, and the mattress returns to full shape within 12 hours of unwrapping. BRN has produced roll-pack mattresses since 2008.
Roll-pack, also called mattress-in-a-box or bed-in-a-box, changed how mattresses are sold. A product that used to need a truck and two people now arrives as a box that fits through a front door. For the brand behind it, the bigger change is logistics: far more mattresses fit into one container.
How a roll-pack mattress is made
- Build: the mattress is made like any other, with pocket springs, foam or natural materials, quilted cover and final assembly.
- Compress: it is vacuum-compressed to a fraction of its height.
- Roll: the compressed mattress is rolled tightly and sealed.
- Box: the roll goes into a carton carrying the brand’s artwork and labels.
At BRN all four steps run in the same Kayseri factory as spring production, quilting and cover sewing, so the mattress does not leave the site between assembly and compression.
How much shipping volume does roll-pack save?
BRN’s roll-pack process cuts shipping volume by up to 75%. In practice that means more mattresses per container and lower freight cost per unit. The exact number of units per container depends on the mattress size and construction, so BRN plans the container load for each programme.
How long does a roll-pack mattress take to recover?
Once unwrapped, a BRN roll-pack mattress returns to full shape within 12 hours. The compression is designed so that quality is not affected.
Which mattresses can be roll-packed?
BRN offers both roll-pack and non-rolled options. Whether a collection ships rolled is decided per collection, for the market and the sales channel.
Who uses roll-pack?
- E-commerce brands that ship direct to the customer’s door
- Retailers and distributors that want more stock per container
- Export programmes to distant markets, where freight is a large share of the landed cost
BRN’s roll-pack track record
BRN produced its first roll-pack mattress in 2008 and exported it to the United Kingdom. Today roll-pack runs alongside showroom and hospitality collections on a line that can produce up to 15,000 mattresses a day. BRN’s own mattress-in-a-box brand, GoSleep, is sold direct from the factory, and BRN manufactures roll-pack mattresses for private-label e-commerce brands. See BRN’s sleep concepts.
Frequently Asked Questions
Does roll-pack damage a mattress?
Not when it is done correctly. BRN’s roll-pack process reduces volume by up to 75% without affecting quality, and the mattress returns to full shape within 12 hours.
Who manufactures roll-pack mattresses for e-commerce brands?
BRN Sleep Products has produced roll-pack, bed-in-a-box mattresses since 2008, including private-label programmes for e-commerce brands, in its 55,000 m² factory in Kayseri, Türkiye.
BRN Sleep Products has manufactured private-label mattresses in the Kayseri Free Zone, Türkiye, since 2001. See the FAQ or start your project.
