Two brothers, John and Rob Merwin, began as liquidators but eventually, quite tenaciously and scientifically started deconstructing mattresses and visiting factories to learn how to design a better mattress themselves. The early days, 1995 to be exact, consisted of a refurbished Wonder Bread truck, a Motorola brick phone, and Rob unloading every mattress in his inventory at any house in the Phoenix, Arizona valley, day or night. John—who was about to marry, but whose path to earning a college degree to support his wife and himself in Montana was rather dismal—agreed to help.

This involved many sleepless nights but after watching three guys hand roll a flattened mattress, John purchased a $135,000 machine from Italy that could do it all. Allowing Brooklyn Bedding to be innovators in the mattress-in-a-box space.

That rarity accounts for the brand’s affordability as well as its quality. Brooklyn Bedding designs and then ships mattresses direct to customers for a fraction of the price of the big guys because the brand’s state-of-the-art factory located in Phoenix, Arizona. Brooklyn Bedding also manufactures many of the top private label mattress brands on the market, having opened its first permanent showroom at the Las Vegas Market trade show in 2018. (In this case, what happened in Vegas did not stay in Vegas.)

In the last two years, Brooklyn Bedding has doubled its production capacity. To keep up with the growing demand, the company built a new 600,000-square-foot factory in Phoenix, Arizona where even more mattresses can be designed and shipped direct to customers’ doors.