JUAREZ, Mexico — In a move designed to enhance its customer service with two-day delivery to most retail partners, bedding manufacturer South Bay International has started production in a 160,000-square-foot facility here.

The vertical factory will allow the company to produce its springs, pour foam and build its boxed bed lineup. Spring production is expected to begin this month, and foam pouring and mattress production is expected to begin in the first quarter of 2022.

The new facility, in tandem with South Bay’s recently opened 100,000-square-foot warehouse in Ridgeway, Va., and its Rancho Cucamonga, Calif., headquarters, gives the company the ability to meet its retail customers’ needs more quickly and to bundle its range of products for delivery.

Toby Konetzny, senior vice president of business development for South Bay International, said the factory in Mexico will help expedite the company’s delivery cycle and help the company meet the growing demand for its products.

“We are at capacity at our facility in California, and we’re looking to expand here as well,” he said. “The opportunity in Mexico makes sense. We already have the workforce there, and the logistics are in place.”

The facility is owned by Keeson Technology Corp., South Bay’s parent company. Currently, South Bay manufactures its mattresses in its 215,000-square-foot Rancho Cucamonga, Calif., facility, and its adjustable bed base line comes from Keeson’s factory in Asia.

Once production is fully operational, South Bay expects to produce 6,000 hybrid and memory foam mattress a month. All of the beds are produced and packaged so that they can be shipped small parcel.

Increased and ongoing demand facilitated the new factory and the new warehouse, Konetzny said.

“We want to be able to offer our customers two choices,” he said. “We understand that handcrafted in the U.S. is important, and we continue to invest in our facility here. The facility in Mexico will give us better price points, and our ability to pour our own foam there will help us control our materials’ supply.

“Our main goal is to increase our output,” Konetzny added. “We have been able to keep up with demand and have been blessed to get new customers. Retailers are looking for domestic solutions for product, and our warehousing solution gives them alternatives, too.”

I’m Sheila Long O’Mara, executive editor at Furniture Today. Throughout my 25-year career in the home furnishings industry, I have been an editor with a number of industry publications and spent a brief stint with a public relations agency where I worked with some of the industry’s leading bedding brands. I rejoined Furniture Today in December 2020 with a focus on bedding and sleep products. It’s a homecoming for me, as I was a writer and editor with Furniture Today from 1994 until 2002. I’m happy to be back and look forward to telling the important stories impacting bedding retailers and manufacturers.

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