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Some of them were thin pieces that looked like they had been removed from other bigger pieces
After I ordered the bag and it was delivered, I let it expand for a couple of days, and then I laid down on it. I could feel bumps all over my body. I opened it up and I could see/feel pieces of foam that had hard spot on it. Some of them were thin pieces that looked like they had been removed from other bigger pieces. I also saw small pieces (couple of square inches) plastic sheets (like from plastic covering for products).
I talked to Amazon and they sent a replacement. When I got the replacement, without taking it out of the box and letting it expand, I opened up the zipper and could see/feel similar pieces with hard surfaces on them.
My guess is the company's quality control has degraded. Probably most of the early bags had relatively good quality control where the foam pieces were cut into smaller and regular shapes, and the hard pieces that were cut were thrown away. With the popularity of the product, maybe they started running out of foam and so they started keeping all the pieces and didn't bother trimming away the harder parts. Also, I got some powdery stuff from the foams - which indicates that some of the foam pieces had dried out and had disintegrated.
I just looked at a couple of pages of 5-star reviews and a couple of pages of 1-star reviews. A great majority of the 5-star reviews are from 2013 or earlier. Most of the 1-star reviews seem to be from 2014 and 2015. This seems to indicate that the earlier products were better in quality than the newer products.
I'm attaching 4 pictures. The first shows the bag with some of the foam taken out. The second picture shows the foam that was taken out of the bag. For what it's worth, from these two pictures, you can see that the foam pieces are not cut into regular pieces and they are not cut into small pieces.
The third picture shows some of the foam pieces that I noticed were hard as I removed handfuls from the bag. It also better shows the varying sizes and shapes, and the irregularity of the shapes. Also, the middle of this picture shows pieces of plastic sheets that were part of the stuffing for the bag.
The fourth picture shows 3 bags that contain the foam I removed from the Fuf bag. The left bag has hard parts to the foam. The right 2 bags have foam pieces that do not have hard parts. However, these two bags have pieces that are sort of crunchy (like they're getting dry), and the pieces vary in softness. Some are thin sheets that are very soft and some are bulky pieces that are dense. Anyhow, from this sample, it appears that 1/3 of the foam has hard parts that would be uncomfortable when you're lying on it.
The description says the bag is "Filled with super soft and long lasting fuf foam re-fuf again and again for custom comfort." Fuf foam must be their name for recycled foam pieces from a variety of sources.
September 2015 · Home and Kitchen