Five things that matter when making a good mattress

By Deluxe Sleep · Published on 28 July 2026

Five things that matter when making a good mattress

A visit to BICO's mattress factory in Schänis reveals a great deal that is fascinating about how a mattress is made. It is impressive how many details have to be considered just so that, in the end, you sleep well.

The following insights come above all from Rocco Cristofaro, Innovation Manager at BICO, and Markus Läser, Head of Production at BICO, who answered questions openly during a factory visit – as did other employees of BICO and of the foam supplier.

1. Foam core and material quality

"The core of a mattress plays a decisive role in whether you wake up in the morning refreshed or tense," explains Rocco Cristofaro, Innovation Manager at BICO. The selection of high-quality foams forms the foundation for restful sleep. Through its collaboration with Foampartner AG of Bubikon, a leading manufacturer of polyurethane (PU) based foams, BICO ensures a high standard of production quality. Without a good core, a mattress cannot deliver good sleep, and with it, long-term satisfaction. It is not only the type of foam that plays a decisive role for comfort and durability, but also its composition and density. Foampartner supplies BICO with many different types of foam – for example, some that are especially breathable, and others where supporting the body is the main focus. For a large range of mattresses, BICO combines different foams, whereas cheap mattresses often consist of only one or two types of standard foam.

"Every sleep system is tested across the four dimensions of bed climate, hygiene, ergonomics and durability. Based on the results and the insights gained from them, we can develop new, even better products. This process is called 'reverse engineering'," explains Konchok Chogye, Head of Quality Management and Good Night's SleepLab at BICO.

2. Hand-crafted covers and individual customisation

"Every fabric behaves a little differently, no machine can do that. It takes a lot of feel," explains Markus Läser, Head of Production at BICO. The craftsmanship of the experienced seamstresses, who work in the large factory hall in Schänis, guarantees a tailored fit and optimal support for the person lying on the mattress. The careful selection of high-quality materials for the covers also ensures a long service life and a pleasant surface. This individual customisation makes it possible to respond to customers' specific needs and preferences, whether in terms of firmness, material or design. And one more thing: BICO relies on sheep's wool from Swiss production, and has thereby even revived an almost forgotten branch of the economy. 26 sheep farms regularly supply sheep's wool for BICO's covers.

"The various work steps are indeed machine-assisted, but we owe the precision of the seams and edges, as well as the exact fit of the components, to the know-how and dexterity of our employees," says Markus Läser, Head of Production at BICO.

3. Technological innovation and research

"We invest continuously in research and development in order to offer innovative solutions for healthy, restful sleep," says Rocco Cristofaro. BICO's development team works on new materials, technologies and designs to make sure the mattresses keep pace with customers' constantly changing needs. From advanced pressure-distribution systems to improved moisture-regulation technologies, every aspect of sleeping is taken into account in order to guarantee an optimal sleep experience. Insights from medicine and ergonomics are also drawn on to continuously improve the mattresses and maximise sleeping comfort. In Schänis, BICO's team has a test laboratory available for this purpose. There, pillows and mattresses undergo endurance tests, covers are washed again and again to check their fit, and a climate chamber simulates how quickly moisture escapes from the mattress after a sweaty night.

4. Environmental compatibility and sustainability

"Sustainability begins with regionality," Head of Production Markus Läser is convinced. BICO is taking steps to minimise its ecological footprint, such as using recycled materials and promoting recycling programmes. Through continuous improvement of its production processes, BICO strives to offer environmentally friendly solutions and to promote sustainable practices. Attention is paid not only to the environmental compatibility of the materials, but also to reducing waste and emissions throughout the entire manufacturing process. A mattress's ecological footprint is still large, partly because of the petroleum-based components needed for the foam. But BICO has set out to shrink it significantly.

5. Value for money and a long-term investment

"A mattress is a long-term investment in health and well-being," emphasises Rocco Cristofaro. Although high-quality mattresses come at a higher price, they offer unbeatable value for money. A considered purchase, based on quality, durability and comfort, pays off in the long run and ensures a restful night's sleep. The lifespan and health benefits of a high-quality mattress outweigh the initial costs. Just think of what an hour of physiotherapy costs. That is why it is important to view the value of a mattress as a long-term investment in sleep quality and well-being.

A detailed report from the mattress factory can also be read in the Galaxus magazine.

Author Martin Jungfer is responsible there, as Head of Content, for all editorial articles.

At Deluxe Sleep, we carry BICO mattresses in our range and are happy to advise you in our showroom in Bischofszell on which model suits your needs.

Source: this article is based on a piece from the BICO sleep blog (bico.ch), which also appeared as a report on a factory visit to BICO in Schänis in the Galaxus online magazine (author: Martin Jungfer). The production, research and quality processes described, as well as all quotations, come from BICO employees.