Production
From formulation to finished mattress — six stages, one roof.
Density is set in the pour, comfort is set in the cure, and nothing leaves the line before inspection.
Production
From formulation to finished mattress — six stages, one roof.
The order matters: density is set in the pour, comfort is set in the cure, and nothing leaves the line before inspection.
Formulation
Polyol and isocyanate are measured to the target density and firmness for each grade.
Pouring & foaming
The mix expands into continuous foam blocks in the foaming line.
Curing
Blocks rest in the curing room until the cell structure has fully set and stabilised.
Cutting
Cured blocks are cut to size — mattresses, sheets, cushions and custom profiles.
Quilting & covering
Sleep products are wrapped in quilted, breathable fabric with finished borders and handles.
Inspection & dispatch
Every piece is checked for density, dimensions and finish before it is packed and delivered.
Foam grades
Density is the number that matters.
Polyurethane foam is graded by density in kilograms per cubic metre. Higher density means more material in every block — more support, slower sagging and a longer life. We pour a range of grades so each product uses the right one.
Densities shown are our standard grades; tolerances and full test data are available on request. [Confirm exact grade list with the factory.]
| Grade | Density | Firmness | Typical use |
|---|---|---|---|
| D16 | 16 kg/m³ | Packaging, soft cushion filling | |
| D18 | 18 kg/m³ | Pillows, toppers, economy mattresses | |
| D22 | 22 kg/m³ | Standard mattresses, sofa backs | |
| D25 | 25 kg/m³ | Premium mattresses, hotel range | |
| D32 | 32 kg/m³ | Orthopedic, sofa seats, hospital | |
| D40 | 40 kg/m³ | Vehicle seats, heavy-duty seating |
The signature
Royal Pillow-Top. Our flagship, made in Borama.
A tufted comfort layer over a D25 high-density core, finished in navy quilted fabric with gold piping and carry handles.
- Two-layer constructionSoft on top, supportive underneath — no sagging in the middle.
- Breathable quilted coverKeeps the surface cool through Borama's warm nights.
- Finished edges and handlesEasy to turn and move; borders hold their shape.