Molded pillow production has been managed by the most advanced robot line technology. The foam’s chemical components must be precisely mixed and injected into a prepared mold.

The unique production technique that includes high-quality molds allows us to produce an identically shaped pillow with perfect contours and edges. Using molds, we can create all those shapes that cannot be obtained by simply cutting off a foam block.

The factory in Serbia can produce 15 different dimensions and shapes of molded pillows:

Contour pillow,
Traditional (“soap” shaped) pillow,
Lumbar cushion,
Travel pillow, etc.

Per customer requirements, pillows can be produced with a gel pad. Different fragrances can be infused as well.

The hardness of pillows can also be adjusted by customer requirements. The pillow can be made with or without holes to improve airflow.

You can see our catalogs of molded pillows here:

These types of foam carry the mark “M,” and we produce them in various densities (18 – 35 kg/m3 ). They have wide usage in the upholstery industry and sleeping equipment industry.These foam types are most often used as a mattress and topper base in our factory.

Products can be made only of conventional foam or combined with different layers of memory, smart, or other foam sorts to achieve some specific comfort and usages. Conventional PU foams are highly durable and elastic, which allows them to stand pressure and weight without permanent deformity.

Besides, we can offer our customers flame retardant (FR) conventional foams for specific applications.

After regular and memory foam blocks foaming on a 250 m long line, the block will be cut and shaped through the most advanced machines. We own 7 CNC machines for long blocks cutting and further cutting preparation, 6 CNC machines for 3D short blocks cutting in different 3D/contour shapes, 3 Carousell machines for high–efficiency cutting of flat foam plates, 2 vertical cut machines, 2 profiling
machines (for multi-zoned mattresses and toppers), 3 crushing machines with rollers for cell structure
opening, 2 machines for foam perforation, and 1 peeling for cutting of foam foil rolls.

Gluing line, as an integral part of the foam cutting line, has been used to complete cores production for final products.

Molded pillow cores are produced by the most advanced robotic line with a capacity of about 80.000 molded pillows per month. We can create contour pillows, “soap” shaped pillows, travel neck pillows, lumbar pillows, sitting cushions, and everything in different dimensions and foam density, with or without perforated holes for better airflow.

Production of conventional PU and memory foams of the highest quality is what we are, next to a wide assortment of final products, recognized worldwide.

In block production, we own a continuous max foam/lay-down foaming line for flexible PU foam. On the 250 m long foaming line, we have been producing 20 and 40 m long flexible PU foam blocks within the density range from 18 to 80 kg/m3. More than 40 dosing lines allows us to foam a wide range of foam types and densities:

Conventional(M) foam, density 18-35 kg/m3
HR(G) foam, density 30-40 kg/m3
AirCell®(Q) foam, density 28-40 kg/m3
Gel AirCell®(Q) foam
Memory (P) foam, density 40-80 kg/m3
Memory (P) foam with gel
Smart (R)-latex-like foam™, density 50-55 kg/m3
Conventional flame retardant (FR) foam
Memory FR foam

Together with their subtypes, all these foam types differentiate by firmness, level of flexibility, and cell structure. Every one of them is possible to combine with another foam type, which makes the choice we offer fascinating.

You can choose any fabric among our numerous samples to get unique preferences, such as innovative fabrics enriched with different yarn components and treatments. For example, fabrics with bamboo fibers, Tencel, or Aloe Vera, which give fabric antibacterial, antiallergenic, and similar preferences that increase sleeping quality and comfort.

Most often, we choose renowned suppliers so we can be able to strictly control quality bats to guarantee better lead time. Of course, you can choose to use your own supplier’s fabrics, own labels, embroidery, and ribbons.

Tailoring and sewing halls own modern machines for fabric processing. Among them, there are 4 single–needle quilting machines, 3 multi-needle quilting machines, two embroidery machines with 20 heads, and 136 kits of sewing machines. Modern quilting machines and embroidery machines allow us to give you a choice between almost unlimited designs for quilting and embroidery motives. This option allows for a more luxurious design, better comfort, and a fantastic possibility to represent your brand through the elements you decide you want. You may choose cover quilting with high-quality hollow fiber or numerous
standard and memory foams, while for your brand logo, slogan, or product name, you may choose almost
any color you imagine.

Thanks to advanced technology and the possibility of doing all the operations inside our production cycle,
we can follow and control every step, guaranteeing the highest quality.

The final products packaging process is done through two primary lines – the mattress/toppers packaging line and the pillow packaging line. You can choose or deliver packaging material yourself, or we can get it for you in the dimensions, design, and shape you desire.

For toppers and mattresses packaging, we use three strong pressing devices that allow us to compress, vacuum into PET foil, roll up and finally pack our products into retail or transport boxes of an appropriate size. We pack pillows through a highly effective line that allows vacuuming and rolling them up, or, if you so choose to, they can come in classic packaging – non-woven bag, box, foil, or similar.

We can optimize the packaging dimensions with a well-elaborated and efficient system and provide better loading space, warehouse, and reduced transport costs.

Our warehouse space covers nearly 15.000 m2 , which provides a high operative level.