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"Eco-World," the Home of the Brain Sleep Pillow
The Brain Sleep Pillow is manufactured at the "Eco-World" factory in the nature-rich town of Kusu, Oita Prefecture. We will introduce the six manufacturing processes carried out there, as well as a secret final process.Process 1: Chips are melted into a liquid, then solidified into fine threads
Process 2: Polyethylene is woven using patented technology!
Through Eco-World's unique patented technology, which has been researched and developed since 1999 and excels in water permeability, breathability, durability, color, and shape, the structure is transformed into a "braided resin mesh structure" by weaving it into a spring-like form. 
At this time, a 3-layer, 9-gradation structure is also built simultaneously, achieving a fit that surpasses custom-made. Afterward, it is molded while being cooled with clean, soft water with few impurities from Oita Prefecture, which is also a rice-producing region.
Process 3: Skilled craftsmen cut to eliminate even a few centimeters of deviation
While regular pillows are often cut by machine, the 9-gradation Brain Sleep Pillow can have its quality compromised by even a few centimeters of deviation. Therefore, skilled craftsmen meticulously cut each pillow, manually verifying the gradation. This ensures that all products maintain a precise 9-gradation structure and high quality.
"Due to the nature of the product, cutting each one individually requires millimeter-level precision. That's why machines can't cut them, so we do it by hand. At first, I couldn't tell where the gradations were at all, but now I can spot them instantly. The president calls me a 'magic cutter' (laughs)."
Process 4: After cutting, the resin is left to rest for 72 hours to stabilize it.
Since polyethylene resin has elasticity, it is left to rest for 72 hours after cutting to stabilize the product.
Process 5: Craftsmen cut and heat-treat
Each piece is visually inspected and cut by craftsmen. Furthermore, the cut surfaces are repeatedly heat-treated to smooth them out and improve the texture. Although it takes time and effort, this is a very important process to deliver a satisfactory product to all customers. In addition, the polyethylene that becomes unnecessary during cutting is re-melted and processed into resin, making it very sustainable.
"Since we use a proprietary, confidential technique, I cannot show you the heat treatment process. However, we use specialized tools and carefully heat-treat each piece by hand, taking our time. We adjust the heat treatment duration and intensity while observing the condition of the cross-section for each product, but only staff who have been in charge of this process for many years truly understand these adjustments (laughs)."
Secret Manufacturing Process: There's also a secret final finishing process that cannot be shown...
In fact, there's one more step added at the very end. Proprietary patented technology is applied to adjust the comfort. Finally, after passing strict inspections, the product reaches the customer's hands.Process 6: Each item is inspected by hand under light and bagged by hand.
The final step is inspection. To check every detail, each item is manually illuminated with a light, and a final visual inspection is performed. It's necessary to ensure there are no foreign objects and that the weave is correct and uniform, so we use a special rounded light that can shine from various angles for clear visibility.
"Packaging is the final stage, so even here, we never skip checks for foreign matter or the shaping of the edges. Since it's something that comes into direct contact with the skin, we take care to ensure customers can use it with peace of mind."
Process 1: Materials are finely crushed.
Process 2: Melted into a liquid and cooled.
Process 3: Formed into small bead-like spheres.
"If the size and shape aren't uniform, it becomes difficult to process, so after forming them into spheres, we sort them and only use the good ones as raw materials again."
"The Brain Sleep Pillow has a 3-layer vertical structure and a 9-layer horizontal gradation. We adjust the softness by changing the thickness and density of the threads in each section. Delicate temperature control is required for manufacturing, so we always pay attention to factors like the day's temperature."