Sealy Korea Opens New Factory in Yeoju, Aiming to Become Asia's Manufacturing Hub

New Factory Built a Decade After Domestic Launch
In-House Spring Production to Begin with 2028 Factory Completion
Small-Batch, High-Mix Production Maintained by Skilled Manual Labor
Rising Popularity of 'K-Beds' Drives Exports to Mongolia and Kazakhstan

"Once the spring factory is completed in 2028, this site will become a key manufacturing hub in Asia, capable of one-stop production from raw materials to finished products. By utilizing domestic components, we will realize the value of mutual growth." (Yoon Jonghyo, CEO of Sealy Korea)

Yoon Jonghyo, CEO of Sealy Korea, is introducing the production facilities and future plans at the newly completed Sealy Bed factory on July 7 in Ogeum-dong, Yeoju, Gyeonggi-do. Sealy Korea

Sealy Korea has completed a new factory in Yeoju, doubling its production area just 12 years after establishing its first plant in the country. Sealy, which anticipates growth in Korea’s premium bed market, expanded its production facilities with the goal of turning this site into its Asian manufacturing hub.

On September 7, inside the production hall of Sealy Korea’s new factory in Ogeum-dong, Yeoju, Gyeonggi Province, the processing of raw materials, sewing, and assembly work was in full swing. The interior of the factory was arranged in a counterclockwise direction according to the three main processes: quilting, sewing, and building. Workers wearing masks and safety goggles were busily sewing fabric in the quilting work area, which adds filling material to the fabric. The quilted fabric then goes through sewing to combine it with springs and the mattress edges, and is further assembled and stitched together with the top panel, sides, and springs to form the complete exterior of the mattress. At the end of the conveyor belt in the production hall, quality control staff were inspecting every part of the mattress, carefully brushing off dust.

A worker is performing the build process by sealing the sewn fabric and assembled interior at the Sealy bed factory in Yeoju. Sealy Korea

Made-to-Order by Hand; Domestic Spring Production in Two Years

In contrast to other companies that boast automated facilities, Sealy maintains a small-batch, high-mix production system based on skilled manual labor. Sealy uses a made-to-order system, producing an average of 303 mattress units per day. Yudongwan, plant manager at Sealy Korea, explained, "Sealy only produces what has been ordered, works to minimize waste at every stage, and implements lean production to ensure that defects from one process are not passed on to the next."

The Yeoju factory consists of a "procurement building" for raw material receipt and inspection, a "production hall" where mattresses are made, and a "logistics building" where finished mattresses and frames are stored. Here, material inspection, production, and shipping are conducted as a one-stop process. The production area spans 15,183 square meters (about 4,593 pyeong), which is about twice the size of the previous factory. The facility is capable of producing 500 mattress units per day (based on eight-hour shifts).

Interior view of Sealy Bed's production building at Yeoju Plant. Sealy Korea

Starting in 2028, the production of springs—one of the core components—will take place at the Yeoju factory. Currently, the core springs are supplied from Australia and China. All raw materials, including springs, foam, fabric, and filling, are brought in only after passing tests at Sealy’s research and development center in Australia. Yoon Jonghyo, CEO of Sealy Korea, said, "This will help us overcome geopolitical risks such as wars and disasters, and will mark an important turning point for the company in terms of stabilizing logistics and supply. As a result, our sales and market share will naturally increase as well."

As Sealy is increasing the domestic sourcing rate for its bed raw materials, the springs produced in Korea will be manufactured using steel wire from POSCO. Yoon explained, "We are currently discussing potential supply plans with companies that receive steel from POSCO, process it, and supply steel wire."

Sealy’s springs are made from titanium alloy and undergo a double heat treatment at 300–400 degrees Celsius. The initial process during spring production is "bailing," which removes the stress from the spring that makes it want to return to its original shape. At the Yeoju factory, an additional "unbailing" step releases the spring from its compressed state. This process involves first removing the stress from the spring, restoring it to its original form, and then conducting a second heat treatment on the completed coil to further enhance its durability.

Exterior view of Sealy Korea's Yeoju Plant. Photo by Sealy Korea

'Made in Korea' Turns Premium, Emerging as Asia's Bed Production Hub

Sealy Korea has expanded its production facilities on the back of fast growth over the past five years. Its accumulated annual growth rate over the past five years has reached 18%. Last year, domestic production volume was 69,000 units, and the goal for this year is 75,000 units. Yoon stated, "While China’s growth has slowed, we have continued to expand and achieved the best performance globally. Despite labor, licensing, and other complex issues that make companies reluctant to establish domestic factories, we determined that self-managed production is necessary to deliver products that satisfy the discerning Korean consumer."

Sealy Korea has set a goal to increase the export share to Asia to 20% in the future. This is based on growing demand for premium beds, and a rising preference for Korean-made products in Southeast Asia. Executive Director Kim Jongmin of Sealy Korea commented, "We are currently producing products for export to China, Mongolia, and Kazakhstan, and we are also discussing exports to Singapore, Hong Kong, and Taiwan."

Over the past 10 years, Sealy has doubled the number of its domestic retail stores. Currently, Sealy beds are distributed at 49 department stores, 16 outlet locations, and 77 retail shops nationwide.

This content was produced with the assistance of AI translation services.