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Tempur Production USA found home in Duffield

November 18th, 2011 1:56 pm by Staff Report

Tempur Production USA found home in Duffield

The Duffield site manufactures Tempur-Pedic mattresses, pillows, mattress overlays and toppers, hospital mattresses, wheelchair pads and other comfort products.

Tens of thousands of mattresses and pillows leave the Tempur Production USA facility in Duffield, Va., each month headed for stores and homes around the world, according to Ken Mitchell, vice president and plant manager, Tempur Production USA.


Founded in the early 1990s by Swedish half-brothers, today Tempur-Pedic is the second largest selling mattress in the country, falling just behind Sealy as the world’s favorite mattress.


The Duffield production facility came on line in May 2001 after Tempur-Pedic’s initial production facility in Denmark could not keep up with the demand for the NASA-inspired mattress. The original creators of Tempur-Pedic, Dan-Foam, had teamed up with Lexington, Ky. resident, Bob Trussel, to sell products in the U.S.


Lexington became home to the company’s corporate headquarters and, when choosing a manufacturing site, the company wanted a location within close proximity to its headquarters. A site selection committee had narrowed the search to two locations: Oak Ridge, Tenn., and Duffield, Va.


Tax incentives, plus Duffield’s skilled and dedicated workforce, sealed the deal for Tempur to open its first U.S. production facility in Duffield, Va. The manufacturing site opened with 85 employees and quickly grew to 300 employees, leveling off today around 250.


The Duffield site manufactures Tempur-Pedic mattresses, pillows, mattress overlays and toppers, hospital mattresses, wheelchair pads and other comfort products. In addition, all Research and Development is done at the Duffield site. Product demand necessitated the need to build a second production facility in Albuquerque, N.M., to handle the western portion of the United States.


When Tempur-Pedic first started, the company carried a limited line of "firm" mattresses. Mitchell explains the company realized this knocked them out of the market for many consumers. Today, the company features three collections from soft to firm, including the Tempur-Cloud Collection, Tempur-HD collection and Tempur Collection. The price point starts at $1,000 and goes up to $7,299 for the King Grand Bed.


Mitchell gives a lot of credit to company’s success to the Duffield employees.


"These are the most flexible and genuinely-driven employees you will ever find. They love making this product, and nothing leaves the factory unless it is perfect."

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