Live Comfortably wraps up Downlite plant integration in 90 days

Boca Raton, Fla. – Three months after announcing its acquisition of Downlite, Live Comfortably has absorbed the company’s manufacturing into its operations.

Live Comfortably, the largest utility bedding in the U.S., recently completed the integration of Downlite’s facility in Mason, Ohio. It joins Live Comfortably’s portfolio of plants in North Carolina, Texas and Virginia.

“The seamless transfer of Mason’s production into our manufacturing network is a key enabler to unlocking the synergies we envisioned from the Downlite acquisition,” said Brian Cassady, CEO of Live Comfortably. “Executing this feat within 90 days of the deal’s closing is a testament to the great efforts put forth by our commercial and operations teams, as well as the migrating Downlite customers and Downlite employees who assisted.”

The migrated production includes poly-filled garnetted pillows, natural fill blown pillows and natural fill comforters. With production concluded in Mason, Live Comfortably plans to redistribute Downlite equipment among its plants.

“The equipment relocations will not only allow us to increase our capacity but will also create production redundancies to strengthen our business continuity plan,” said Bryan Vaughn, Live Comfortably’s VP of Manufacturing. “The incremental capacity will be beneficial as we scale up to meet demand from our recently expanded Serta license.”

See also: Serta boosts long-term licensing deal with Live Comfortably

Live Comfortably acquired Downlite’s home and hospitality utility bedding business in March.  Downlite has been long known for its strength as a manufacturer of natural fill pillows and comforters and its portfolio of brands. including Ralph Lauren, Tommy Bahama, Primaloft and Pendleton.

Downlite is also the US’ only domestic manufacturer of mattress pads and protectors, which it produces at its factory in Monroe, N.C. Live Comfortably acquired those product lines as well, which continue to be produced in Monroe.

“When we studied Downlite prior to the acquisition, it was apparent that our production speeds were faster than Downlite’s, with lower staffing levels,” said Ken Woung, Live Comfortably’s COO. “As we have migrated production from Mason into our plants over the past few weeks, we have proven out the projected efficiencies. We are able to manufacture the migrated products more swiftly, without sacrificing quality.”

The Mason integration is Live Comfortably’s third in the past 24 months, each creating gains in production efficiencies. In 2024, the company closed its Pico, Calif., plant and consolidated production into its other plants. In 2025, Live Comfortably closed a factory in Henderson, N.C., again absorbing production into its remaining plants.