Quality control in pillow core production spans the entire process from raw material procurement to finished product delivery, involving several key stages. The following are the main quality control points to ensure product safety, comfort, and compliance with standards.
1. Raw Material Procurement and Inspection
Raw materials are the foundation of pillow core quality and must be strictly controlled:
Supplier Evaluation: Select qualified suppliers with stable production and a sound quality management system, and sign quality assurance agreements.
Raw Material Testing: Each batch of raw materials must be tested for indicators such as color, fiber length, loft, and cleanliness to ensure no impurities or contamination.
Chemical Safety: Test polyester fibers, memory foam, and other materials for formaldehyde content, pH value, and volatile organic compounds (VOCs) to ensure compliance with national standards such as GB 18401.
2. Filling Process Control
Precise control of process parameters is required in processes such as opening, mixing, and shaping:
Temperature and Humidity Management: The workshop environment must maintain suitable temperature and humidity to prevent fibers from absorbing moisture and clumping or accumulating static electricity.
Filling Uniformity: Multi-stage opening and combing equipment ensures complete fiber separation and prevents clumping, improving filling consistency.
Functional Additives: Adding ingredients such as bamboo charcoal granules or plant extracts requires even distribution and must not produce any irritating odor.
3. Filling Weight and Density Control: Filling weight and density directly affect the pillow's support and lifespan.
Quantitative Filling: Automated filling machines with weighing systems ensure the filling weight error for each pillow core is controlled within a reasonable range (e.g., ±5%).
Density Matching: Monitoring the foaming or compression process according to product design requirements (e.g., 45D, 50D memory foam) ensures the density meets standards.
4. Sewing and Sealing Quality: Pillowcase sewing is a crucial step in preventing filling leakage.
Stitch Standard: The stitch length for synthetic fiber pillowcases is generally 5 stitches/cm, for the pillow core leather 4 stitches/cm, and for the straps 3.5 stitches/cm, requiring uniformity.
Sealing Position: Pillow inserts typically have a 30cm opening in the center for filling. After sealing, check for symmetry and secure sealing.
Thread Color Matching: The sewing thread color should be similar to or the same as the fabric to avoid color differences affecting the appearance.