Industry Overview
Polyurethane (PU) foam mattresses are cellular-structured products valued for their softness, elasticity, resilience, light weight, and air and moisture permeability. Polyurethane was introduced in 1937 and subsequently found applications across industries including footwear, furnishing, building, and automotive products. Its properties have also made PU foam suitable for pillow and mattress manufacturing.
The production of PU foam involves a controlled foaming and polymerization process in which pressure and vacuum conditions are adjusted to obtain the desired foam structure. Water is used during production and can be recycled. The resulting foam is formed into blocks that are subsequently carved and processed for mattress applications.
PU foam mattresses are evaluated on characteristics such as resilience, compression, ultimate tensile strength, bearing loss, compressive strength, bearing capacity, and density. They generally provide medium-level support and are widely used because they are affordable, readily available, and lightweight. PU foam can also be incorporated into hybrid mattresses as a comfort layer. However, its durability is comparatively limited, and it may collect dust and allergens more readily than some other foam types. Overall, PU foam mattresses remain a practical option for households seeking comfort while controlling product costs.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 240 Nos./Day |
| Land & Building (11075 sq.mt.) | Rs. 2.46 Cr |
| Plant & Machinery | Rs. 1.97 Cr |
| Working Capital for 2 Months | Rs. 4.16 Cr |
| Total Capital Investment | Rs. 8.96 Cr |
| Rate of Return | 74% |
| Break Even Point | 32% |
Content Index
- INTRODUCTION
- MARKET PROSPECTIVE
- CONSTRUCTION
- SIZES
- PROPERTIES OF PU FOAM MATTRESS
- RESILIENCE
- SOLVENT RESISTANCE
- ANTIBACTERIAL PROTECTION
- YELLOWING AND DISCOLOURATION
- LOW FIRE RETARDANCY
- ADVANTAGES AND DISADVANTAGES OF A POLYURETHANE MATTRESS
- ADVANTAGES
- DISADVANTAGES
- USAGE AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS DESCRIPTION
- FOAMING PROCESS:
- FOAM CURING:
- QUALITY CONTROL
- PLANT AND MACHINERY
- REQUIRED MACHINE FEATURES
- MARKET POSITION
- MAJOR COMPANIES
- MATTRESS MARKET IN INDIA
- MATTRESS MARKET IN INDIA (USD BN)
- BRANDED MATTRESS MARKET IN INDIA (% OF OVERALL MARKET)
- BRANDED MATTRESS MARKET BY MATTRESS TYPE (% OF BRANDED MATTRESS MARKET)
- MATTRESS MARKET BY PRICE POINT (% OF BRANDED MATTRESS MARKET)
- MATTRESS MARKET BY DISTRIBUTION CHANNEL (% OF BRANDED MATTRESS MARKET)
- MATTRESS MARKET BY DISTRIBUTION CHANNEL-2018
- MATTRESS MARKET BY REGION (% OF OVERALL MATTRESS MARKET)
- MATTRESS MARKET BY DISTRIBUTION CHANNEL-2018
- MATTRESS MARKET BY CONSUMER TYPE (% OF OVERALL MATTRESS MARKET)
- MATTRESS MARKET BY CONSUMER TYPE
- GROWTH DRIVERS OF MATTRESS MARKET IN INDIA
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- 6. TRANSPORTATION:
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TOTAL LOAD:
- 8. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- PLANT LAYOUT
- SUPPLIERS OF PU FOAM MATTRESS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIER OF CHEMICALS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIER OF PRODUCTION LINE
- SUPPLIER OF STITCHING MACHINE
- SUPPLIERS OF DG SETS
- SUPPLIERS OF POWER TRANSFORMER
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF EXHAUST FAN
- SUPPLIERS OF TESTING EQUIPMENTS
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
A PU foam mattress is a mattress made primarily from polyurethane foam, a cellular synthetic material known for softness, elasticity, and resilience. The foam structure provides cushioning and medium-level support, making it suitable for residential and other bedding applications. PU foam is also lightweight and can be used as a comfort layer in hybrid mattress designs. Its characteristics can vary according to density, cell structure, and formulation, which influence factors such as firmness, resilience, compression performance, and overall comfort.
PU foam is used as the cushioning and support material in mattress construction. During manufacturing, polyurethane foam is produced through a controlled foaming and polymerization process, after which the resulting blocks are carved and processed into suitable forms. The processed foam can then be incorporated into mattress assemblies with appropriate coverings and other components. The report also describes foaming and foam curing as key stages of the manufacturing process, followed by quality control to ensure the finished material meets the required characteristics.
The main properties include resilience, compression characteristics, ultimate tensile strength, bearing loss, compressive strength, bearing capacity, and density. These properties influence how a mattress responds to body weight, repeated loading, compression, and everyday use. PU foam is also characterized by softness, elasticity, and permeability to air and moisture. The appropriate combination of these characteristics depends on the intended mattress design and required level of comfort and support.
The main advantages of PU foam mattresses are affordability, light weight, wide availability, and suitability for many household applications. PU foam can provide a reasonable level of comfort and medium support while helping manufacturers control product costs. Its lightweight nature also makes it convenient to handle and allows it to be incorporated into hybrid mattress designs as a comfort layer. These characteristics make PU foam a practical material for manufacturers targeting accessible mattress products.
PU foam mattresses have limitations related to durability, heat management, and dust or allergen accumulation. The report describes the life span of PU foam as comparatively short and notes that PU foam may not perform as well as coil mattresses in summer conditions. PU foam can also collect dust and other allergens more easily than certain other foam types. Product performance varies with formulation, density, construction, ventilation, and covering materials, so these factors should be considered when selecting or designing a mattress.
A PU foam mattress manufacturing plant should consider raw-material availability, market access, power and fuel supply, water supply, climate, transportation, waste disposal, labor, regulatory requirements, taxes, site characteristics, community factors, and fire or flood control. Plant layout and production equipment are also important because they affect material movement, operational efficiency, safety, and quality control. The report specifically includes plant location factors, principles of plant layout, plant and machinery, required machine features, and project implementation scheduling.
Quality control should verify the physical and performance characteristics required for the intended PU foam mattress application. Important parameters include density, resilience, compression behavior, tensile strength, compressive strength, bearing capacity, and related performance characteristics. Manufacturing controls should also cover the foaming and curing stages because process conditions can influence the resulting foam structure and properties. Appropriate testing equipment, process monitoring, and applicable B.I.S. specifications can help maintain consistent product quality.
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