Behind the scenes · The workshop chapter

How ourCocobellasofas areMade.

Sophie Conran goes on a visit to our John Lewis sofa workshop to see how these wonderful sofas are made

A bolt of Sophie Conran stripe on the cutting table at the Preston workshop

I am very proud that our John Lewis Cocobella sofas are made by hand here in the UK. I recently went up to the workshop in Preston, Lancashire, to meet the team of wonderful people there. The workshop was founded over 50 years ago and was recently voted the UK's best upholstery manufacturer. Walking around the workshop spaces with Jamie, who heads up all the workshop operations was super interesting and a lot of fun too!

Sophie Conran with Jamie, who heads up operations at the Preston workshop — The workshop
Walking around the workshop spaces with Jamie, who heads up all the workshop operations.

The cutting table

We started by seeing how the fabric is carefully laid out on a very high tech computerised cutting table. The computer can automatically work out how to best use each piece of fabric to ensure the maximum level of usage whilst at the same time, ensuring that all the patterns will match up perfectly. In our case, this means all of our stripes align and look fabulous on each sofa.

The computerised cutting table with fabric laid out ready to cut — A very high tech computerised cutting table

The sewing team

Next we visited the very skilled team that sews together all the covers so beautifully. It was truly amazing to see how perfectly they sew each and every cushion and cover.

Hands guiding a sofa cover through an industrial sewing machine — Each and every cushion and cover

A machinist at the Preston workshop sewing a sofa cover — The very skilled team that sews together all the covers

Card pattern templates hanging on the workshop wall

The frame

Then we visited the frame making team and learned how each frame is made using solid birch hardwood. I was very impressed to discover that every single frame they are making for us is guaranteed for 25 years!

Sophie Conran looking through a bare birch hardwood sofa frame — Each frame is made using solid birch hardwood

A frame maker fixing webbing to a birch hardwood sofa frame — Guaranteed for 25 years

A fishmouth spring

Our sofas have a special type of spring in the base, called a fishmouth spring. This type of spring gives the front edge of the sofa a lovely springy feeling and has the benefit of both helping you get out more easily and being more comfortable to sit in.

Fishmouth springs being fitted into the base of a Cocobella sofa frame — Fishmouth springs
This type of spring gives the front edge of the sofa a lovely springy feeling.

Upholstering the frame

Next, we went to see how the frame is upholstered. Every little detail is considered extremely carefully and very skilfully done - I was amazed by how many different layers are inside the sofas

An upholsterer smoothing wadding over a Cocobella sofa frame — How many different layers are inside the sofas

Covers and cushions

The last step was watching how the covers are fitted for the first time and the cushions going on too. Each cushion is made with a combination of feather and foam from plant based materials. It means that the amount of plumping you need to do is very reduced compared to a feather and down cushion. In the US, we also offer Hypoallergenic Fibre Fill – a soft, resilient alternative that mimics the feel of feathers while remaining entirely allergy-friendly.

A striped cover being drawn over a finished Cocobella sofa — The covers are fitted for the first time

Two upholsterers fitting a striped cover at the Preston workshop — And the cushions going on too

Steamed by hand

It’s really amazing to see how quickly the sofa goes from being an upholstered frame to looking like a gorgeous sofa. Each one is steamed by hand and the final result is truly fabulous.

An upholsterer steaming the striped cover of a finished Cocobella sofa — Each one is steamed by hand

I really loved my visit and feel extremely happy to know that every one of our sofas that are made for John Lewis is put together with so much love.

Sophie Conran