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From Home Furnishing Business
Essentia Opens Manufacturing Facility in Boca Raton
October 15,
2025 by Karen Parrish in Business Strategy, Industry 
Essentia Organic Mattress, the pioneer in eco-luxury sleep and health-driven design, announced the opening of its second manufacturing facility in Boca Raton, Florida, its first in the United States and a major milestone in the brand's 20-year journey. The expansion establishes Essentia's dual manufacturing footprint across North America in both the U.S. and Canada, marking a new era for sustainable production and wellness innovation.
Designed as the largest Certified Organic mattress factory of its kind, the new facility combines high-volume capacity with Essentia's signature Beyond Latex™ organic foam. The Boca Raton operation can now produce one mattress per minute—scaling to over 1,000 per day—while maintaining Essentia's uncompromising commitment to organic purity and performance. Every mattress is built with Essentia's patented Beyond Latex™ organic foam technology, engineered to deliver superior comfort while reducing exposure to household toxins, VOCs, and EMFs.
"This is more than an expansion, it's the heartbeat of Essentia's next chapter," said Jack Dell'Accio, Essentia founder and CEO. "Our Boca Raton home brings innovation, sustainability, and performance together under one roof. We're honoring our Canadian roots while expanding opportunities in the U.S. and beyond."
By producing in the U.S., Essentia can meet demand more quickly, create sustainable jobs, and reinforce that eco-luxury is a viable and growing segment of American manufacturing. The company continues to operate its original Canadian facility, where it has spent over two decades perfecting the proprietary organic foam technology that now powers its U.S. production. Together, these facilities represent a vertically integrated North American manufacturing footprint built on innovation and sustainable craftsmanship.
The Boca Raton facility also introduces the CellRegen Lab, featuring the Human Regenerator Jet Bed—a breakthrough recovery system utilizing Cold Atmospheric Plasma (CAP) therapy, once reserved for elite athletes. With this innovation, Essentia expands its mission to make advanced recovery and longevity technologies accessible in everyday wellness spaces.
It also features an Essentia Organic Mattress showroom, an immersive space where visitors can experience the mattresses and shop the full range of organic sleep products—bringing innovation, wellness, and luxury directly to the customer.
From its partnership with Delos's Stay Well program in esteemed hotels such as MGM, Bellagio, and more to collaborations with biohacker Dave Asprey on performance mattresses designed for recovery and longevity, Essentia has consistently anticipated wellness trends before they reach the mainstream. The Boca Raton expansion continues that legacy, merging eco-luxury with American. manufacturing excellence to advance wellness-driven innovation on both sides of the border.
As consumers demand healthier homes, transparency, and sustainable design, Essentia stands at the intersection of two powerful forces reshaping today's economy: the resurgence of American manufacturing and the rapid growth of the global wellness market.
"Essentia is more than a mattress company, it's a movement," added Dell'Accio. "This expansion empowers us to deliver recovery, resilience, and better health at scale, whether in Canada, the U.S., or worldwide."
Essentia's Boca Raton expansion marks a new era of sustainable manufacturing—where organic innovation, recovery technology, and performance-driven luxury come together to redefine how the world sleeps.
To learn more about Essentia Organic Mattress and its wellness innovations, visit www.myessentia.com