Family-owned business reveals how it makes its five-star comforters

Emerald Pellot

 

Downlite is a family-owned and operated bedding company based in Ohio. The business manufactures pillows, mattresses, blankets and throws but its comforters are really the star of the show.

The comforters start from the inside out with Downlite’s premium down and down alternative filling. The stuffing is inserted into one of two types of comforter shells: baffle box or sewn thru. 

Baffle box shells have 20 to 40 pre-sewn chambers that look like a grid of squares stitched into the fabric. Calibrated machines are used to pack each chamber with the pillow filling. Finally, the shells are cleaned, sewn shut and law labels are added. 

Sewn thru shells begin with one giant empty chamber. Each is filled with the down or down alternative. Then a worker ensures the stuffing is evenly distributed to prep it for sewing. Next, the shell is placed under a giant sewing machine that stitches in horizontal and vertical lines. 

To ensure quality control, an inspector marks the comforters for imperfections with red tape. Finally, the completed comforters are bagged, boxed and distributed.

Customers seem to be quite satisfied with their purchases. Check out some of Downlite’s five-star reviews.

“We like our comforter. It’s everything they say it is. Soft, warm. The perfect weight whether it’s warm or cool out, it’s just right,” one person said.

“I kid you not when I say that I can spend the entire day wrapped up in my new comforter! It’s the most comfortable comforter I have ever owned. It feels so good on my body and keeps me very warm,” another wrote.

“My experience with Downlite was awesome! It was easy to place the order, the merchandise arrived in record time and the quality of the items I purchased was impressive. I was very impressed with the company and wouldn’t hesitate to order from then again,” a customer said.

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