Efficient Conversion
We plan cutting layouts carefully to improve material yield and reduce avoidable waste during production.
Responsible Manufacturing
Our Commitment
to Sustainability
We are working to reduce waste across our foam conversion and upholstery supply operations through better material use, responsible sourcing and the recovery of suitable production offcuts.
Our Approach
Reducing Waste Through Better Material Use
Foam conversion naturally creates offcuts as blocks are trimmed and components are cut to size. Our aim is to make the best possible use of these materials rather than treating every offcut as general waste.
Offcut Reuse
Usable offcuts may be retained for suitable smaller jobs, packing applications or future production requirements.
Material Recovery
Suitable foam waste can be recovered and used in the production of reconstituted foam products.
Reconstituted Foam
Giving Foam Offcuts Another Purpose
Our production process creates foam offcuts in a variety of shapes and sizes. Where suitable, these materials can be collected and incorporated into the manufacture of reconstituted foam blocks.
Reconstituted foam, sometimes called recon or chip foam, is produced by bonding together recovered polyurethane foam pieces to create a dense and durable material.
01
Foam is converted
Blocks and sheets are cut into customer components.
02
Suitable offcuts are separated
Recoverable material is kept apart from unsuitable waste.
03
Material is processed
The recovered foam is broken down and prepared for rebonding.
04
New recon blocks are produced
The bonded material forms dense foam blocks for further conversion.
Recovered Material
Reconstituted Foam Blocks
Dense foam products manufactured using bonded foam pieces.
Material Applications
Where Reconstituted Foam Is Used
Its high density and durability make reconstituted foam suitable for a range of demanding support and protection uses.
Contract Seating
Firm support layers for commercial seating, benches, bar seating and high-use furniture.
Protective Packaging
Dense protective components for equipment, machinery and industrial packaging applications.
Impact and Load Support
Support pads, packing pieces and components requiring a dense, durable foam material.
Natural Filling Options
Natural Materials for Upholstery and Cushion Making
Alongside synthetic fillings, we supply a range of natural and traditional filling materials for upholstery, furniture restoration and specialist production work.
Traditional Filling
Animal Hair Blends
Traditional resilient filling materials used within upholstery, restoration and furniture construction.
Plant-Based Fibre
Coir Fibre
Natural coconut fibre used for firm upholstery filling, support and traditional furniture construction.
Soft Filling
Feather Fillings
Soft natural fillings for scatter cushions, upholstery and premium comfort applications.
Ongoing Improvements
Practical Changes Across Our Operations
Sustainability is an ongoing process. We continue to review how materials are purchased, stored, converted, packed and dispatched across our operation.
Improving cutting yield and production planning
Separating suitable foam offcuts for recovery
Reviewing packaging use and material efficiency
Consolidating deliveries where practical
Material Advice
Looking for a More Suitable Material?
Speak to our team about reconstituted foam, natural fillings or alternative materials for your application.