Bean bags are a popular type of furniture made from a fabric sack filled with small polystyrene beads. Big Joe is one of the most well-known bean bag brands. But what exactly is inside their bean bags? Let’s take a closer look.
The Outer Shell
The outer shell of a Big Joe bean bag is made from a durable fabric. Most Big Joe bean bag covers are made from a soft yet sturdy material called SmartMax. This patented fabric is tear resistant, stain resistant, and water resistant.
SmartMax has a velvety feel and comes in a variety of colors and patterns. It is double stitched for maximum durability. The supple fabric conforms nicely to the body when you sit or lie on the bean bag.
The Filler
Inside every Big Joe bean bag is a high quality polystyrene bead fill. Polystyrene beads are inexpensive to produce and very lightweight. They compress easily when you sit on the bean bag to provide cushioning and support.
Each individual bead is approximately 3-4 mm in diameter. Big Joe uses virgin polystyrene beads, meaning they are brand new beads specifically manufactured for use in bean bags. The beads are not recycled from other products or uses.
Virgin polystyrene beads have a smooth, round shape that allows them to flow freely within the bean bag. This gives the bean bag its moldable, fluid-like quality. As you shift position, the beans quickly redistribute to conform to your body.
Expanded vs Regular Polystyrene
Big Joe bean bags are filled with expanded polystyrene beads. Also known as EPS beads, expanded polystyrene beads are made by expanding polystyrene through a heating process. This causes the beads to puff up with air pockets.
EPS beads are extremely lightweight with a density of about 1.05 g/cm3. Regular or dense polystyrene beads that have not been expanded have a density of about 1.04–1.09 g/cm3.
While not a huge difference, the expanded polystyrene beads are lighter weight. This gives Big Joe bean bags an overall lighter and airier feel compared to bean bags filled with regular polystyrene beads.
Polyester Fiber Fill
In addition to the polystyrene beads, Big Joe bean bags also contain some polyester fiber fill. This acts as a cushioning pad and helps the beads maintain their shape.
Polyester fibers interspersed among the tiny polystyrene beads prevent them from compacting too densely. The fibers give the fill an extra fluffy and pillow-like quality.
Polyester fill is also quite resilient, springing back readily after compression. It enhances the bean bag’s ability to regain its shape after prolonged use.
Fill Amount
How much fill is inside a Big Joe bean bag? Fill amounts vary slightly depending on the size and style of bean bag.
Here is an overview of the typical fill weights for popular Big Joe bean bag models:
| Big Joe Bean Bag | Fill Weight |
|---|---|
| Big Joe Dorm Bean Bag Chair | 2.5 lbs |
| Big Joe Milano Bean Bag Chair | 3 lbs |
| Big Joe Lumin Bean Bag Chair | 4.5 lbs |
| Big Joe Roma Bean Bag Chair | 6 lbs |
| Big Joe XL Fuf Bean Bag Chair | 9 lbs |
| Big Joe King Bean Bag | 10 lbs |
| Big Joe Ace Bean Bag Chair | 55 gallons |
As you can see, fill weights range from just a couple pounds for smaller dorm-sized bags up to 55 gallon capacity for their largest Ace model. More fill means a bigger, fuller bean bag with more support.
Quality Control
Big Joe maintains rigorous quality control standards for their bean bag fills. All of their polystyrene beads go through strict safety and purity inspections. Their manufacturing facilities are certified safe and environmentally friendly.
Here are some key qualities that Big Joe checks for with all bead shipments:
- Bead color consistency – The beads should have a uniform white color without discolorations.
- Bead size uniformity – The bead diameter should consistently be 3-4 mm without irregular sizes.
- Bead sphericity – Each bead should have a perfect, smooth spherical shape.
- No clumping – The beads should flow freely without clumping together.
- Purity – The polystyrene beads cannot contain any foreign material or impurities.
- No static – There should be no static charge buildup when beads pass through equipment.
Big Joe also adheres to all applicable laws and regulations regarding the use of polystyrene beads. They guarantee their bead fills are non-toxic and completely safe.
Third Party Testing
For further assurance, Big Joe bean bags are tested by independent quality control laboratories. Samples undergo a battery of assessments for:
- Lead content
- Phthalate content
- California Proposition 65 compliance
- Consumer Product Safety Improvement Act compliance
All Big Joe bean bags must pass these third-party safety tests before leaving the manufacturing facility. The test results validate the high purity and safety of their bead filling.
The Benefits of Polystyrene Bead Fill
Using polystyrene beads brings a number of important benefits for Big Joe bean bags:
Lightweight
The lightweight nature of expanded polystyrene beads keeps the bean bag highly portable and easy to move around. Even their giant 6 foot and 7 foot bean bags are manageable for one person to carry and reposition.
Moldable
The smooth round EPS beads move and conform to your body’s contours. This creates a personalized fit and cradling comfort.
Durable
Polystyrene beads are durable and resistant to deformation. They retain their spherical shape well over years of use. The fill maintains the bean bag’s supportiveness and does not get lumpy or flattened out.
Affordable
Polystyrene beads are an inexpensive filling material. This allows Big Joe to produce quality bean bags at very reasonable prices.
hypoallergenic
Polystyrene beads are inherently hypoallergenic. They do not contain materials that typically cause allergic reactions. This makes Big Joe bean bags suitable for people with sensitivities.
Safety Considerations
While polystyrene bead filling has many benefits, there are some safety considerations to keep in mind:
Choking hazard
The small polystyrene beads pose a potential choking risk for young children. Bean bags should be kept away from toddlers and babies who might open the liner and ingest beads.
Flammability
Like most plastics, polystyrene has a low ignition point and can burn rapidly. Bean bag owners should avoid exposing them open flames or other high heat sources.
Static charge
Polystyrene beads tend to build up static electricity charges through friction. This static can be released when a person gets on or off the bean bag. The intensity varies based on environmental humidity and other factors.
Off-gassing
There are minor concerns about off-gassing from polystyrene beads. Off-gassing refers to the release of volatile organic compounds (VOCs) from the materials over time. However, studies show bean bags emit minimal VOCs well within safety limits.
Environmental impact
Polystyrene takes hundreds of years to degrade in landfills. Some environmental advocates caution against its use due to sustainability concerns. However, Big Joe bean bags can be used for many years before disposal to maximize their lifecycle.
Care and Maintenance
With proper care, the polystyrene bead filling in Big Joe bean bags can provide many years of enjoyment. Here are some tips for maintaining your bean bag fill:
- Fluff the beans frequently by kneading the bag with your hands. This helps keep the fill well distributed.
- Avoid exposing the bag to moisture which can cause beads to clump.
- Keep away from excessive heat to prevent melting or distortion of the beads.
- Spot clean stains on the outer cover promptly to prevent them migrating into the fill.
- Consider having the bag professionally refilled if it begins feeling too compacted or flattened out.
Conclusion
When you get comfy and sink into the supple, enveloping comfort of a Big Joe bean bag, you’re feeling the magic of expanded polystyrene beads! The lightweight EPS filling perfectly conforms to your body while maintaining resiliency. Combined with the cozy SmartMax outer cover, it makes for an incredibly comfortable seating experience. With proper care, a Big Joe bean bag can provide many years of reliable comfort and support.