Many things have changed since the Joyce brothers placed their first advertisements in the Boans Family Annual and the Settlers Handy Pamphlet in 1915. Established in the Western Australian town of Fremantle, the company’s earliest products included jute and cotton twines, calico and linen bags and sacks.
In 1918, a new factory was purchased, and by 1922, the product range started to change with the production of silky down mattresses made of kapok.
By 1929, one of the firm’s most successful products, the Night’s Ease Roll Edge Mattress, was rolling off the production lines. Sales were given a boost by the news that the Duke of Gloucester slept on a Night’s Ease mattress during his 1934 visit to Australia.
In 1949 the company was sold to Thomas and Co. A year later land was purchased at O’Connor, and over the next seven years a new factory was built on this twenty acre site. This plant produced canvas goods, steel and wooden furniture and was the largest innerspring mattress facility in Western Australia. During the 1960’s a foam line was built to provide the foam for the mattresses.
In 1941, the British company Cable Makers, built a cable-making factory at Moorebank, Sydney. In 1953, Cable Makers learnt about polyurethane foam while visiting Bayer in Germany. Bayer consequently offered Cable Makers the first licence outside Europe to manufacture this new material. Foam production started in 1955 and Cable Makers became the first polyurethane foam producer in Australia.
Even then, innovation was at the core of the company’s philosophy. In the following years management commissioned the manufacture of its first purpose-built foam machine. It trademarked one of its most successful products Esta-Foam, and was the first to introduce one-shot ether foams to Australia.
The Cable Makers Foam Division continued to grow, and in the early 1960’s built an independent foam division with sophisticated handling and cutting equipment for 30 metre long blocks. Continued growth justified further expansion with foam factories in South Australia, Queensland and Victoria being built during the 1970’s.
The launch of reticulated foam manufacturing was a significant Joyce innovation. Joyce designed and built a “reticulation chamber” which has since been sold to companies in the USA, China, Taiwan, Korea, Indonesia and India.
In 1985, the Joyce business in WA was bought by a group of investors who in 1988 also acquired the Cable Makers Foam Division, thus establishing Joyce Foam Products as a national foam business.
In 2005 Sheela Foam Pty. Ltd., the largest manufacturer of foam in India, purchased the company and the focus on innovation intensified. Improvements to processes and products were introduced at every opportunity, culminating in the consolidation of production in Moorebank in 2012.
The installation of VPF (Variable Pressure Foam) technology in 2011 was a major breakthrough, virtually eliminating emissions from foam production. This process also improved the quality and range of foam products. VPF continues to be used today to make a range of high quality foams, ideal for applications in the bedding, furniture and acoustics industries.
Joyce’s focus on health and environmental considerations has been an ongoing goal. The year 2000 saw the addition of allergy-reducing technology to mattress foams and in 2007 Joyce was the first foam company to gain Good Environment Choice Australia (GECA) certification. In 2012 this was extended to the full range of Joyce products. CompriShield™ is Joyce’s latest environmental innovation. It is a natural, sustainable, bio-based microbial control solution which gives mattresses lifetime protection from mould, mildew, dust mites, bed bugs and odour.
The growth of Joyce has always depended on a hard-working and enthusiastic workforce. To ensure Joyce has the highest calibre of sales and management staff, Joyce introduced a graduate recruitment program in 2009 to give graduates an opportunity to develop and grow with the business.
If you’ve got a great story about Joyce, we’d love to hear from you. Send us an email [email protected], or call your local Joyce sales representative on 1800 021 304.