Specialty Manufacturing
Resident Home Mattress
Jeffersonville, IN
Project Overview
When Resident Home—the parent company of leading direct-to-consumer bedding brands like Nectar—needed to establish a massive, advanced mattress manufacturing and distribution hub, Kimmerle Group acted as their comprehensive, long-term partner. Our engagement began long before the building design phase; deep due diligence led to the selection of a premier industrial site in Jeffersonville, Indiana, positioning Resident Home perfectly within a major national logistics corridor.
Engineering the Process Flow: From Raw Materials to Roll-Pack
Transforming a sprawling warehouse footprint into a high-capacity, automated manufacturing plant required an obsessive attention to industrial process flow. Our team programmed the facility to seamlessly transition high-volume raw materials into compressed, retail-ready products.
The structural and layout strategy successfully accommodates every distinct phase of the production line:
Raw Material Staging & Storage: The facility features dedicated, wide-span zones for the staging and organization of large-scale foam core components prior to assembly.
High-Density Advanced Racking: To maximize vertical cubic space and optimize inventory management, we integrated cutting-edge, high-density automated racking systems. This heavy-duty infrastructure allows for the safe, systematized vertical storage of high-volume manufacturing blocks.
Automated Assembly Lines: The main production floor utilizes heavy industrial conveyors and precision assembly machinery, ensuring a continuous, fluid workflow that minimizes material handling times.
Precision Roll-Packing & Labeling: At the culmination of the assembly line, mattresses are fed into advanced compression and roll-packing machinery. This specialized station automatically compresses, rolls, wraps, and labels the product for direct-to-consumer shipping.
Logistics & Pick-and-Pack Outflow: The finalized products are seamlessly funneled into the brand's signature high-visibility blue shipping boxes. The space features an optimized "pick and pack" outbound logistics zone, engineered to support rapid loading and high-throughput third-party logistics (3PL).
By combining master-level architectural planning with rigorous industrial space planning, Kimmerle Group helped Resident Home realize a state-of-the-art manufacturing powerhouse. The Jeffersonville facility stands as a blueprint for modern, automated direct-to-consumer fulfillment, proving that operational efficiency and architectural precision are inextricably linked.
