22,500+sq. ft.
Manufacturing Facility
Advanced Foam Manufacturing
Built to Manufacture.Engineered to Perform.
From foam selection and precision cutting to finished products and private-label packaging, Gajanan Polyfoam delivers scalable manufacturing solutions under one roof.
OEM, private-label and customised bulk manufacturing
Production active
Capacity100K+Units monthly
Density range4–60 kg/m³
Product categories100+
PU FoamMemory FoamHR FoamMoulded FoamRebonded FoamCNC CuttingPrivate Label
100,000+units
Monthly Production Capacity
4–60kg/m³
Available Density Range
100+categories
Product Manufacturing Range
01 / FacilityManufacturing Infrastructure
One Facility. Multiple Foam Solutions.
Our 22,500+ sq. ft. manufacturing facility supports product development, precision cutting, foam fabrication, finishing, inspection and packaging.
With a monthly capacity exceeding 100,000 units, we can support product trials, growing brands and continuous high-volume supply programmes.
Bedding & SleepFurnitureAutomotiveHealthcareRehabilitationHospitalityPackagingPrivate Labels
02 / CapabilitiesManufacturing Capabilities
Precision at Every Stage
Flexible production capabilities allow us to manufacture standard products as well as customised foam components.
01↗
CNC Foam Cutting
Computer-controlled foam cutting for accurate dimensions, repeatable shapes and bulk production.
02↗
Profile Cutting
Custom profile cutting for mattresses, cushions, acoustic foam and specialised industrial applications.
03↗
Contour Cutting
Ergonomic contour development for cervical pillows, lumbar supports and rehabilitation products.
04↗
Compression Packing
Space-efficient compression and roll packing designed for economical storage and transportation.
05↗
Custom Fabrication
Foam shaping, bonding, laminating and finishing according to drawings, samples or application needs.
06↗
Cover & Branding
Product covers, embroidery, labels, inserts and customised packaging for private-label customers.
03 / MaterialsFoam Expertise
Materials Designed Around Performance
Foam grades can be selected according to firmness, resilience, pressure relief, durability and application.
PU Foam
Versatile polyurethane foam for furniture, mattresses, cushions, packaging and general applications.
HR Foam
High-resilience foam engineered for improved bounce, durability and long-term seating comfort.
Memory Foam
Pressure-responsive foam for pillows, back supports, seat cushions and premium sleep products.
Moulded Foam
Consistently shaped foam components for automotive, furniture and specialised comfort products.
Rebonded Foam
High-density bonded foam suitable for firm seating, flooring, mattresses and industrial applications.
04 / ProcessProduction Workflow
Six Steps From Concept to Dispatch
A structured workflow helps maintain accuracy, repeatability and clear communication across every order.
Requirement Analysis
We understand the product application, dimensions, density, firmness, quantity and packaging requirement.
Material Selection
The appropriate foam grade and raw materials are selected according to performance and commercial needs.
Sample Development
A prototype or production sample is prepared for shape, comfort, finish and specification confirmation.
Precision Production
Approved products move into controlled cutting, contouring, moulding, bonding or fabrication.
Quality Inspection
Dimensions, density, appearance, finish and packaging are inspected at multiple production stages.
Packing & Dispatch
Products are packed according to order requirements and prepared for safe, organised dispatch.
Multi-stage inspectionQuality Built Into Production
Inspection checkpoints are applied from incoming material to finished packaging.
QC
ControlledProduction workflow
05 / QualityQuality Assurance
Checked Before It Reaches Your Customer.
Our inspection process helps identify dimensional, material, finishing, branding and packaging issues before dispatch.
✓Raw-material inspection
✓Foam density verification
✓Dimension and tolerance checks
✓Shape and contour inspection
✓Cover stitching and zipper inspection
✓Branding and label verification
✓Compression recovery checks
✓Final packaging inspection
06 / PartnershipOEM & Private Label
Your Product. Your Brand. Our Manufacturing.
Develop customised foam products with your preferred size, density, firmness, fabric, colour, logo, label and retail packaging.
Custom dimensionsDensity selectionFabric and coloursLogo embroideryBrand labelsRetail packaging
Start your manufacturing enquiryGet MOQ, sampling and pricing information.
Send your product specifications or reference image directly to our team through WhatsApp.
Discuss requirement onWhatsApp→+91 80530 33512