Why Change Sleeping Mats?

Price can come at a cost and in our heart of hearts we always knew we were playing second fiddle to the big guys. We tried, but the limited technology available to us prevented development the sleeping mats we always wanted. We had moments, normally after a few beers, when we discussed starting our own factory but we knew this wasn't realistic. So like 95%* of companies in the outdoor industry we are always going to have to partner with factories who manufacture for us. The skill to this is finding the owners and managers that have an understanding of, and a passion for quality outdoor gear.

We have always known which sleeping mat manufacturer we wanted to work with and after 3 years of meeting them at various international trade shows everything clicked into place. Prior to this we had sampled sleeping mats from at least 5 other factories but they were the same old that we already had. The quality wasn't any better, the prices about the same and the technology for future development lacking. When we met with Philip we knew he had the same passion as us for developing high quality products. This was the corner stone of his business and he passed this onto every employee. But, and it was a big but, the timescale to release a range in early 2010 was always going to be tight.

We had to draw on Philip's knowledge of producing sleeping mats for over 20 years before trying anything fancy. Unlike every other manufacturer, the base to Philip's manufacturing was a unique PU coating which he developed in the mid 1980's. I'm sure the gear heads reading this will know we're not the only brand using this technique. The PU coating offers a much more stable medium to bond the fabric together with the foam than using a TPU laminate. It also has a much higher melting point than a laminate reducing the risk of a de-lamination in a hot tent or car.

We have based our new range on three clear categories, nothing earth shattering but solid, based on tried and trusted manufacturing techniques. We have experimented with different fabrics, foam types and densities but ultimately all our mats have been made just as you would a cheese toasty. Imagine the bread is your fabric, the butter is the PU coating or laminate and the cheese is the foam. Put it all in a big oven and give it a good squeeze. Cheap thin white bread with a Swiss Emmental would be pretty light. A thick crust rustic loaf with a good Wensleydale would be a meal in itself. I am sad to say there is nothing more complicated to making 99%* of mats in the world than that. The key to making an exceptional mat is the care and attention to detail ensuring every stage of the process is done to the highest standard it can be.

However everything is a compromise, if you want a lightweight sleeping mat it won't be as durable. If you want a super warm pad it sure ain't going to be light. We feel we have specified the most appropriate fabric and the right thickness of foam to offer any customer a mat suitable for them. And we can be sure every pad we send out  has been rigorously tested in the field and in the factory. Once made, every single one of new range of mats is inflated to a stupidly high pressure, tested in a massive water bath and then it is left for 24 hrs inflated. Only if it passes these tests do we send it to you.

I am super psyched with our 2010 sleeping mat range, its been hard work but worth it. However now 2010 has been rubber stamped I can get on with some of the projects we are embarking on for 2011. We have been sitting on some ideas for years and now we have a partner who can make those ideas come alive.

Exciting times then, Jim.

*Totally made up stats but probably pretty close to the mark.

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alpjim