Foam & Compression Specialists
SparkHome’s new modern foam production factory enables SparkHome to control the process from raw materials to finished product. This ensures our customers get consistency, quality, wide range of products and value for money. The factory deals with many large customers in most markets including Costco, Delta Children.
  • Foam Mattresses/Beds
    Foam Mattresses/Beds
  • Foam Furniture: Kids/Lounge Furniture/Bean Bags
    Foam Furniture: Kids/Lounge Furniture/Bean Bags
  • Kids Play: Matts/Indoor Play/Crash Matts/Rocking Toys
    Kids Play: Matts/Indoor Play/Crash Matts/Rocking Toys
  • Pet Beds
    Pet Beds
  • Sporting: Tackle Pads/Gym box
    Sporting: Tackle Pads/Gym box
  • Pillows & Cushions
    Pillows & Cushions
Foam Production
PU Foam is made from a chemical reaction between polyols and isocyanates chemicals. This forms a flexible, open-cell structure filled with air bubbles. When the chemicals and catalyst are mixed they slowly expand, a large mould is used to shape the foam into the large brick shape like you can see on the left, these are usually 50meters long. Density is controlled by the processing time, while hardness is controlled by the formula. Hardness is important to the structure and integrity of the product.. The large 50m lengths of foam are then stored for 2 days to set before they are ready to cut and use. These large slabs are moved with a crane with claw hand mounted from the roof and escalators. The 50m foam lengths are then cut into smaller slabs according to the customers requirements, these can be moved with escalators or forklifts.
Testing
SparkHome conducts ongoing testing on the foam (density and hardness) to ensure we are using the correct density and hardiness on the right products. SparkHome also measures the compression rations and rebound rates to ensure we give the customers what they need. The compression ratio can very from 30% to 85%, usually products are compressed to 85% for maximum container loadings. But the smaller the compression ratio the higher the rebound ratio is, thus reducing the compression ratio increases the rebound ratio.
Automated Cutting Machines
SparkHome have fully automated cutting machines that ensure products are made consistently and to the highest quality. 3D cutting machines cut the slab of foam into the desired shape needed for the final product, this is particular good for larger items that can be cut from one piece of foam.
But it can also cut multiple smaller pieces to maximise the foam waste and bring costs down.
SparkHome have fully automated machines that ensure products are made consistently and to the highest quality. laser cutting machines can cut any shape or design that you want. This enables SparkHome to customise any customer request for matts.
Fabrics
SparkHome work with the best fabric suppliers to prove the most appropriate fabrics for each customers needs. Each supplier has a range of fabrics that vary from entry level to high end fabrics, some of the high end fabrics are restricted to design retailers only. Some of the key fabric suppliers SparkHome work with are: OTE, Davis, MRJ Fabrics, Rainbow and Lazy Bear.



Sewing
SparkHome uses technology and innovation on its sewing lines to finish products to the highest standard. Automatic sewing machines provide a high level of consistency and quality to all products. Innovation help works do their jobs easier and more effectively, these simple innovations help reduce cost and waste.





Compression
SparkHome uses technology and innovation to compress products. The main benefit is to improve container loadings for larger items, but it also improves smaller items where multiple products can be compressed together in a smaller box size. Whether you are compressing for smaller boxes, compressed pack sizes or online sales the saving in shipping is a massive benefit.