CASE STUDIES

Serta Simmons Bedding, a prominent mattress and bedding manufacturer, sought to consolidate operations from two outdated facilities in Janesville and Beloit, Wisconsin into a single, modern manufacturing facility.

• The facility needed to span approximately 500,000 square feet to accommodate expanded production capacity, improved efficiency, and streamlined distribution.
• To retain their skilled workforce and maintain their market presence, the site had to be within close proximity to their existing facilities.

Throughout design and construction, Zilber Property Group (ZPG) leveraged their build-to-suit expertise, addressing the manufacturer's specific operational requirements and challenges.

Highlights of the project:

• A 37-acre site just two miles from Serta Simmons Bedding's original Janesville location was quickly identified as an ideal location.
• ZPG incorporated a special ventilation system to mitigate excessive dust buildup, addressing a critical challenge in their manufacturing process.
• A specialized fire suppression system was developed to safely manage the combustible nature of memory foam materials used in production.
• The move to the new facility was coordinated to occur seamlessly over a single weekend, minimizing operational downtime.
• ZPG also acquired Serta Simmons Bedding's previous facilities in Janesville and Beloit, ensuring a streamlined transition and simplifying ownership logistics.

ZPG successfully delivered a 501,172 square foot, state-of-the-art manufacturing facility designed to meet Serta Simmons Bedding's current and future needs.

• The modern consolidated facility significantly enhanced production capabilities, operational efficiency, and working conditions.
• Despite rising material costs and potential delays, ZPG managed the project's budget and schedule by proactively sourcing materials and fostering strong partnerships with contractors.
• Serta Simmons Bedding retained its skilled workforce and maintained its 40-year presence in the Janesville area, continuing to positively impact the local community.