The in-house manufacturing process
At our plant in Village Billa, District Panchkula, Haryana, we maintain complete operational control across every phase of production. We formulate our own chemical foam, coil tempered steel springs, quilt jacquard fabrics, and package finished bedding for direct freight delivery.
Panchkula facility production floor walkthrough: foaming, assembly, and packaging.
Village Billa, HaryanaEight verified stages of production
Standard operating procedures from chemical receiving to final dispatch clearance.
Raw materials
Sourcing and inspection of chemical polyols, spring wire, and woven textiles.
Every batch begins with raw material verification. Chemical polyols and isocyanates are tested for purity and reactivity, while high-tensile carbon steel wire is verified for consistent tensile strength.
Foam production
Liquid polyol compounding into continuous blocks in chemical foaming lines.
Precision metering dispensers blend raw polyols into continuous reaction molds. The foam rises, expands uniformly into large blocks, and cures under controlled ambient conditions.
Foam cutting
Computerized horizontal slicing, peeling, and CNC profile contouring.
Automated slicing tables carve cured foam blocks into exact sheet thicknesses and custom anatomical profiles with strict millimeter tolerances.
Core assembly
Spring coiling, pocket encasement, and multi-layer structural bonding.
Tempered pocket spring units and foam support layers are assembled and bonded into resilient structural cores with perimeter edge encasements.
Stitching and quilting
Automated multi-needle fabric quilting and precision tape-edge closing.
Heavy-duty computerized quilting machines stitch cushioning patterns into breathable jacquard fabrics. Dedicated tape-edging operators then seal the mattress borders.
Quality control
Batch inspection for core density, rebound resilience, and seam integrity.
Completed units undergo physical inspections. Technicians audit layer adhesion, surface flatness, perimeter rigidity, and stitch consistency prior to packing.
Packaging
Heavyweight protective polymer wrapping, compression, and roll-packing.
Mattresses are sealed in airtight polymer film. Units scheduled for long-distance transit can be hydraulically compressed and roll-packed to optimize cargo volume.
Dispatch
Direct factory freight loading for wholesale dealers, hotels, and institutions.
Consignments are loaded directly at our Panchkula factory loading bays onto dedicated freight vehicles for direct, middleman-free delivery to commercial partners.
Schedule an on-site factory inspection
Wholesale buyers, hospitality purchasing directors, and dealer prospects are welcome to inspect our Panchkula production lines and material stock in person.