Project Detail	Specification
Customer	Mattress and foam products retailer in Apia, Samoa
Product	Uncovered PU foam mattress cores
Core Density	25D
Single Mattress Size	99 × 190 × 7.6 cm
Double Mattress Size	137 × 190 × 7.6 cm
Packaging	Individually bagged, vacuum-compressed rolls
First Container	216 rolls physically loaded
Repeat Orders	3 × 20GP container orders
Production Lead Time	Approximately 20–25 days

1. Customer Background: Finding a More Reliable Foam Supplier

The customer had previously sourced foam mattress cores from another Chinese supplier, purchasing at least three full containers annually. However, recurring shipment shortages and inconsistencies in shipping documents created operational difficulties.

The retailer was also looking to develop its uncovered foam mattress core business and gradually expand into related products, including mattress covers, pillows, and finished mattresses.

The buyer approached Jiangyuan in September 2024, seeking a supplier capable of providing custom-cut foam, bulk compression packaging, and more dependable order coordination.

For a retailer operating in Samoa, where replacement stock must travel a long distance by sea, consistent specifications and accurate shipment documentation are essential to inventory planning.

2. The Main Challenges

Custom Mattress Sizes Without Local Cutting Facilities

The customer required mattress cores in two non-standard dimensions: 99 × 190 cm for single mattresses and 137 × 190 cm for double mattresses.

The buyer also explained that local cutting and compression facilities were unavailable. The products therefore needed to be cut, packaged, and compressed in China before shipment.

Efficient Container Loading

Shipping costs and container capacity directly affected the buyer’s landed product costs. The customer needed an appropriate balance of single and double mattress cores, with compression packaging designed to maximize the use of available container space.

Consistent Materials and Usable Foam Offcuts

The buyer had experienced problems with foam scraps from a previous supplier that could not be reliably recut into foam chips for pillow filling.

This highlighted the importance of discussing material suitability and intended secondary applications rather than treating every foam order as a standard commodity purchase.

Accurate Shipping Documents

The customer had previously encountered discrepancies involving shipped quantities, commercial invoices, and packing lists. Such inconsistencies could complicate customs clearance and create additional administrative work.

The new supplier needed to establish a clear process for shipment verification and documentation.

3. Our Solution: Customized Foam Production and Compression Packaging

Jiangyuan developed a product and packaging arrangement around the customer’s actual sales requirements.

Custom-Cut PU Foam Mattress Cores

The main product was 25D PU foam mattress cores in two primary sizes.

• Single mattress core: 99 × 190 × 7.6 cm, approximately 3 inches thick.
• Double mattress core: 137 × 190 × 7.6 cm, approximately 3 inches thick.
• Supplementary option: 99 × 190 × 5 cm single mattress cores.
• Additional material: Thin foam sheets in selected densities for the customer’s proposed pillow-filling applications.

The customer initially requested a thickness of approximately 7 cm. Jiangyuan converted the specification to 7.6 cm to correspond to a 3-inch mattress core and allowed additional material during cutting to help achieve the intended thickness after compression and recovery.

The product mix could also be adjusted between single and double mattress sizes according to the buyer’s inventory requirements.

Vacuum Compression for Bulk Shipping

Each mattress core was placed in a PE bag before being grouped and rolled for vacuum compression.

The initial packaging arrangement used approximately six single mattress cores per roll or two to three double mattress cores per roll, depending on the product configuration.

The target roll diameter was approximately 30 cm, subject to the mattress dimensions and loading arrangement.

Before production, the team prepared a container-loading estimate based on the selected product mix. This allowed the buyer to review the expected roll quantities and packaging configuration before manufacturing began.

Shipment Documentation and Quality Coordination

To address the customer’s previous documentation concerns, Jiangyuan coordinated commercial invoices, packing lists, and sales contracts around the actual shipment quantities.

The team also supplied available factory and material documentation, including OEKO-TEX and ISO 9000-related documents, and responded to questions concerning formaldehyde, CFCs, VOC emissions, and Safety Data Sheets (SDS).

These documents and statements were intended to help the buyer evaluate material requirements and prepare for importation.

4. Project Execution: From the First Order to Repeat Shipments

The cooperation began in September 2024 with product discussions, specification confirmation, and sampling arrangements. The first order was confirmed in October, followed by shipment in November 2024.

The customer subsequently placed additional orders in January and July 2025. Across the three orders, the product mix and packaging arrangements were adjusted in response to the buyer’s requirements.

Managing Shipment Discrepancies Transparently

The first container had a documented quantity discrepancy: the invoice listed 223 rolls, while the physical shipment contained 216 rolls.

Rather than leaving the discrepancy unresolved, Jiangyuan reissued the relevant documents according to the actual loaded quantity and provided a stamped short-shipment statement. The outstanding quantity was arranged for replenishment in the following shipment.

A further shortage involving six packages of double mattress cores, equivalent to 18 sheets, was identified during the second shipment cycle. The missing quantity was prioritized for replenishment in the next container.

These situations reinforced the importance of quantity verification, consistent documentation, and clear communication throughout the export process.

Adjusting Packaging for Better Container Utilization

During the third shipment, the roll diameter was adjusted to approximately 24–25 cm to address container-loading efficiency.

The team also supplied five additional compressed foam rolls at no charge and discussed reserving additional packaging capacity for future shipments.

For buyers ordering bulky foam products, these adjustments illustrate why packaging specifications should be evaluated alongside foam dimensions and density, rather than after production has finished.

5. Results: Three Container Orders and Broader Product Discussions

The cooperation developed from an initial mattress-core order into a repeat-order relationship.

Three 20GP Container Orders

The customer placed the first order in October 2024 and returned with additional orders in January and July 2025. The three orders were shipped between November 2024 and August 2025.

Faster Inventory Turnover

In a message dated September 9, 2025, the customer reported that the latest container had arrived and sold out in less than two months.

This feedback indicated that the product was moving through the customer’s local sales channel quickly and supported discussions about increasing replenishment frequency. The buyer’s original purchasing pattern was at least three containers per year, with a stated goal of moving toward quarterly replenishment.

Expansion Beyond Mattress Cores

The customer also began exploring additional product categories, including mattress cover sewing, memory foam pillows, and spring mattresses.

These inquiries created opportunities to discuss a broader product range rather than limiting future cooperation to uncovered foam mattress cores.

A More Established Supply Relationship

As the cooperation progressed, the customer raised further requirements relating to payment terms, bill-of-lading control, and potential expansion through a new branch.

6. What This Project Demonstrates

This Samoa project highlights several practical considerations for international buyers sourcing compressed PU foam mattress cores.

Custom dimensions matter. Mattress cores can be produced to specified length, width, and thickness requirements, subject to confirmation of the final production specification.

Packaging must be planned around the container. Roll diameter, mattress size, product mix, and packing configuration all influence how much product can be loaded.

Export documentation needs to reflect actual shipments. When a quantity discrepancy occurs, timely document correction and clear supporting statements help the buyer manage import procedures.

Repeat orders benefit from continuous adjustment. Product proportions and packaging arrangements can be reviewed as the buyer gains experience with local demand and shipping conditions.

For mattress manufacturers, wholesalers, and retailers, working directly with a foam manufacturer can provide a practical way to coordinate material specifications, cutting, compression packaging, and bulk supply through one production partner.

Frequently Asked Questions

Can you manufacture foam mattress cores in custom sizes?

Yes. Jiangyuan can discuss custom-cut PU foam mattress cores based on the buyer’s required dimensions, thickness, density, and order quantity. Final specifications should be confirmed before production.

What foam density was used in this Samoa project?

The main mattress cores used 25D PU foam. Additional thin foam sheets were discussed in selected densities for potential pillow-filling applications.

Can foam mattress cores be vacuum-compressed for export?

Yes. Foam mattress cores can be individually bagged and vacuum-compressed into rolls where the product specifications and packaging method allow. The appropriate roll diameter and loading arrangement should be confirmed for each order.

How many compressed foam rolls fit into a 20GP container?

The quantity depends on mattress dimensions, the number of sheets per roll, roll diameter, and the proportion of single and double mattress cores. In this project, the first container physically contained 216 rolls. This figure is a project-specific reference, not a guaranteed loading quantity for every order.

How do you handle a shipment quantity discrepancy?

Shipment quantities should be checked against the actual loading records. If a discrepancy occurs, the relevant shipping documents can be corrected and supporting documentation provided, with any agreed outstanding quantity handled through a confirmed replenishment arrangement.

Can I request a quote for a full container of foam mattress cores?

Yes. Buyers can provide their required mattress sizes, foam density, thickness, single-to-double product ratio, estimated quantity, and destination port. Jiangyuan can then evaluate the production requirements and prepare a proposed packaging and container-loading plan.

Discuss Your Foam Mattress Core Project

Looking for a manufacturer that can supply custom-cut PU foam mattress cores for wholesale distribution or retail markets?

Zibo Jiangyuan Foam Products Co., Ltd. works with buyers to coordinate foam specifications, custom cutting, compression packaging, and bulk export orders.

Send us your mattress dimensions, density requirements, product mix, and target quantity. Our team can review your requirements and discuss a suitable production and container-loading arrangement.