Cushion fill should not make a noise down or otherwise. I am very familiar with down seats and backs and have never heard an insert make a noise. Perhaps the noise is not actually coming from the fill, it may be the frame. I would question the sales staff at the store since they sell the brand they must be familiar with this issue. I would think that if it makes noise now it will not go away.

You are correct northwestcoast, Their are several types of down proof ticking, a particular type that can be used is more stiffer material because they use a coating which helps a lesser quality material hold the feathers in. Combine this with feathers that have a larger quill which rubs against the ticking and each other will make this noise. This noise may lessen to a degree, mainly because you just get use to it.

My sectional has down cushions and there is a little crinkle noise when I lean back.

It's not that big of a deal to me. I wouldn't count on the noise going away or diminishing a whole lot.

Thank you for your comments about down, I am not going to buy the down couch as I could not live with that sound/sensation.

I just got back from a weekend sectional-hunting trip, and found two sofas in my price range that I liked: the Flexsteel Thornton and Macy's Kenton. I like the rolled arms of the Thornton, however the Kenton has the edge because it is 38" deep, while the Thornton is only 37". That one inch means a lot to my back:). Does anyone know "who" manufactures the Kenton, and how is the quality compared to the Thornton?

I also noticed the same sound in some brands, both high-end and some mid-range, but not others. You can post questions on Macys website.

http://www1.macys.com/shop/product/kenton-fabric-3-piece-chaise-sectional-sofa?ID=724637

Their are several types of down proof ticking, a particular type that
can be used is more stiffer material because they use a coating which
helps a lesser quality material hold the feathers in.

I'm so glad to see that this has been someone else's experience, too, because I'm sending a sofa back due to that issue. The one I purchased was not a lesser brand, but I just can't live comfortably with that constant crunching sound in my ear. When I've shopped for down comforters, I've been told that goosedown doesn't make a noise, but some of the "lesser bird" feathers will. I'm considering switching back to all-foam filling out of desperation.