Our Story

Way back in 1991, Zambia saw an emerging foam manufacturing unit in this small town of Ndola, situated in in the Copperbelt province of Zambia. Since then, foam industry has historically been dominated by only a a few manufacturers. In a vision to create an impact in the foam industry, an entrepreneurial mission to imprint a footprint of foam industry began. With a vision of Mr. Dhiru .G. Patel, founder of perfect products. URest Foam Ltd was launched in the year 2001.Our foam since inception has been manufactured with the latest Technological Machinery. The objective was to produce foam on limited scale before penetrating the broader foam market in the country.

Over the years this Company has grown from a small plant to a Fully Automated Foam Manufacturing Unit. From Naked Foamsheet & Cushions, it grew to produce Foam Mattress, Pillows, Spring Mattress and also Beds. The demand grew for its uncompromised quality and prompt service beating the boundaries of a small town to neighboring towns, from there to neighboring provinces. We have opened our second plant in Chililabombwe Town to cater for the neighboring market. Today our foot prints are firm in the Copperbelt Province. We have not limited ourselves to Copperbelt, but are expanding into the Northern, Eastern and Southern Provinces of Zambia.

Chapter 1

PRODUCTION PROCESS

The Technologically Advanced Machinery such as Continuous Foam Plant and Batch Foam Plant allow for high production capacity of quality foam in a variety of foam grades. The Foam plant produces rectangular blocks and the batch foam plant creates round blocks used for peeling. The main raw materials used include Polyol, Toluene Di-isocyanate, various blowing agents, surfactants, catalysts and colours. After Production the Foam Blocks are cured for twenty-four hours in the block store. Thereafter Foam Block is cut in the conversion department on carousels, band saws and peeling machine.

The foam is cut into various shapes and sizes to suit the needs of the end user. The superior quality is reflected in the consistency of the “U Rest” which relates to the comfort and density which governs the lifetime of the Foam.

What Makes Us Unique? The only Foam Company carrying a 5 year warranty on Mattress in the Country; Value is added through an intimate understanding of the client’s production processes and differentiated needs in order to meet their specific manufacturing requirements; A cohesive working environment enhances transparency and generates trust; The experience gained within the furniture and bedding industries has enhanced our ability to optimize on foam applications; Flexibility with regard to product specifications is accommodated; The Emphasis placed on customer satisfaction ensures a high level of responsiveness and superior service;

Chapter 2

FOAM APPLICATIONS

Flexible polyurethane foam is an important raw material in various industries such as furniture, bedding, automotive, packaging, toy, medical and other related industries. The versatility of flexible foam as a cushioning material that can be cut and shaped accordingly, has proven to be highly effective in furniture. The great advantage of polyurethane foam is reflected in the ability to respond to specific requirements for each application in terms of density and hardness. Various foam configurations are used in furniture seats, backs and arms.

AUTOMOTIVE Flexible polyurethane foams are used extensively for interior components of automobiles, for example: in seats, headrests, armrests, roof liners, dashboards and instrument panels.

PACKAGING Polyurethane foams is highly appropriate material in protecting both light and heavy pieces of equipment and delicate electronic components. Due to high shock absorbing capacity, fragile glasswork, TV’s, Audio sets, PC’s and printers are wrapped in foam sheets.

TOYS: Foam is widely used in the toy industry as it is safe, soft and comforting component that can be handled by children. Some examples of foam usage include: foam blocks, puppets, jigsaw puzzles, dolls, baby toys, sport game sets, stress balls and educational toys.

FURNITURE: The versatility of flexible foam as a cushioning material that can be cut and shaped accordingly, has proven to be highly effective in furniture. The great advantage of polyurethane foam is reflected in the ability to respond to specific requirements for each application in terms of density and hardness. Various foam configurations are used in furniture seats, backs and arms.

BEDDING: A variety of foam combinations utilizing flexible, rebond and peeling foam are selected to suit different comfort level of mattress preference. Foam usage can be found in foam bedding, U REST FOAM LTD. REST ON T HE B EST 3 futons, waterbeds, headboards, armrests, roof liners, dashboards and instrument panels.

MEDICAL: Within the medical industry there are various foam cushioning applications including protective garments, prosthetic cushions, wheelchair pads and pressure point pads. Viscoelastic “memory foam” and high resilient foam mattresses are being used more extensively based on their orthopedic properties.

Chapter 3

PRODUCT RANGE

FLEXIBLE POLYURETHANE FOAM This is supplied in foam blocks, sheets, cut parts, profiles. In the development process, we are currently in the process of bringing in Convoluted Foam.

FOAM MATTRESSES Foam Mattresses are supplied in poly cotton, spun bond and PVC in king, queen, double, three quarter and single sizes.

REBOND FOAM This particular foam is made from Off-cuts generated in the foam conversion process which eliminates foam wastage. It is supplied in blocks, sheets, cut parts and profiles.

LAMINATED FOAM Flexible and rebond foam combinations is laminated to suit particular applications.