From liquid to block, from block to the loading dock.

The order is translated into the density and hardness the application requires. Raw material ratios are adjusted to the target value and to ambient temperature — the same recipe does not give the same result in winter and summer, and this correction is made for every batch.

The mix goes into the mould and the reaction begins. The foam rises on its own heat and builds its cell structure within minutes. There is no intervening at this stage; the block is the result of its own chemistry.

A freshly poured block is not cut immediately. The reaction continues inside for a while and the block is held until it stabilises. A block cut too early will change its dimensions later.

The round block rotates, the blade peels one continuous layer and an uninterrupted roll comes off — from 3 mm to 50 mm. The offcut waste of sheet cutting all but disappears with this method.

Rectangular blocks are cut into sheets, strips or straight to the customer's dimensions. Furniture and mattress producers receive the foam in their own size and do not run a second cutting operation at their plant.

Flame lamination uses no adhesive: the foam surface is melted with a controlled flame and bonds to the fabric. The bond stays thin and the material keeps its flexibility and breathability.

Density and hardness are measured for every batch and thickness tolerance is checked. If values fall outside the order window, the block does not go to the customer.

Roll products are vacuum compressed; volume drops sharply and the square metres carried per container rise. The loading plan is worked out in advance from the dimensions of the order.