Inside Vacuum Packaging: How a Sofa Fits in a Box

The process starts by removing the legs and detaching the backrest where possible. The seat and back are then rolled around a cardboard core, expelling air from the high-resilience foam.

A vacuum seal removes the remaining air, and the roll is banded and slipped into a thin PE carton. On arrival, the customer cuts the seal, the foam re-expands over 24–48 hours, and the sofa returns to full shape.

The magic is in foam recovery rate. We specify foams that rebound to 95%+ of original loft, so the unboxed sofa feels identical to a traditionally shipped one — without the shipping penalty.