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 MATTRESSES:
mattresses are the finest composition of a
strong base made of Rubberised coir and soft sleeping surface of a
thin layer of polyurethane foam to provide smoothness. It has been
medically proved that mattresses are the safest between lumpy cotton
and damaging rubber/foam mattresses.
Polyurethane mattresses have excessive softness and the body sinks
into them like a curved bow that is the main cause for back
problems. Unlike rubber/polyurethane mattresses, mattresses do not disintegrate. These are
treated with some special chemical agents to make them hygienic,
germ resistant, which makes a perfect bed in tropical conditions,
since they do not become hot in summer or cool in winter.
mattresses are used in most -- Homes --
Hospitals -- Tourist bungalows – Hotels, etc. Fowler Bed mattresses
are made for use in Hospitals. Similarly, mattresses can be especially made for various
sports events such as wrestling, Judo etc.
TYPES OF MATTRESSES
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Rupa Standard: This mattress comprises
of rubberised coir pasted with 13mm P U Foam and then covered
with jacquard cotton handloom tapestry cloth with the monogram on the entire area of the
cloth.
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| Rupa Super: This mattress comprises of
rubberised coir pasted with 13mm P U Foam and then covered
with superior quality printed cotton cloth with the cover
being stitched on automatic tape edge machine.
Pearl Rupa
Super: This
mattress comprises of rubberised coir covered with superior
quality printed cotton cloth quilted with 13 mm P U Foam on
one side with the cover being stitched on automatic tape edge
machine. |
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Health Line: This mattress comprises
of heavy density rubberised coir covered with very superior
quality cotton cloth quilted with 20 mm high density P U Foam
on one side and the other side pasted with 13mm P U Foam with
the cover being stitched on automatic tape edge
machine.
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| Royal Sona
Deluxe:
This mattress comprises of heavy density rubberised
coir covered with very superior quality printed cotton cloth
quilted with 20 mm high density P U Foam on one side along
with 16 mm high density P U Foam pasted on the same side and
the other side pasted with 13mm P U Foam with the cover
stitched on automatic tape edge machine. |
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Springer: This mattress is made from best of
imported bonnel high strength springs. They come in variety of
sizes and thicknesses and can be custom made to your
requirement. |
CARPET UNDER LAYS made of
selected springs of coir fibre, carpet underlay are manufactured in
thickness of 10 mm to 25 mm with Hessian cloth backing to
provide smooth surface. Spread underneath wall to wall carpet
or living room carpets, these add to the deep pile comfort and
protect the carpet from moths and vermin. These help reducing
noise of stamping feet and squeaking shoes and in case of
falling of delicate articles save breakage. Life of carpet is
thereby enhanced several times.
| carpet underlay are installed in several
5 star hotels which add as spectacular touch of grandeur by
its tempting and soft touching cushions. SEATS AND BACKRESTS seats and backrests have varied usage.
These find place in buses, railway coaches, transport and
defence vehicles, shipbuilding, cinemas, theatres, auditorium
and several other such places. seats are made in moulded or non moulded
form. These can be given shapes, contours/curvatures as per
drawing/design. seats are non pilferable have more
tensile strength and also economical when compared with other
seat, back rest cushioning materials.
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AIR
FILTERS
Air fillters are widely used for room air
conditioners, centralised air conditioning plants and air handling
units, wherein the filtration of air is necessary to the extent of 5
microns. air
filters made of cross layers of fibre blended with latex and
chemicals, provide passage for air to pass through and change
directions many a times, resulting in deposition of about 98% of
particles, thus ushering the maximum ventilating efficiency. Air
filters are available in standard sizes for almost all models of Air
Conditioners and can be tailor made to the requirement of customers,
available in thickness ranging from 6 mm to 50 mm. Further, central
a/c plants air filters are manufactured with or without wire frame.
Wire frame and chicken mesh are provided to give rigidity, strength
and long life to the filters. The demand is fast changing from
metallic and other Air filters to Air
filters in view of filtration efficiency and cost
effectiveness.
OTHER ITEMS:
has its place everywhere. pillows, chair and sofa
cushions, bath mats are a few other useful and attractive household/
office items. can be
adopted in many ways industrial as well as institutional. To mention
a few, can be
used as: - insulation material - decorative panels for walls -
packaging pads for electronic equipment and heavy machines -
automotive filters - wrestling/Judo and other sports mattresses -
inner sole shoe lining - pads for unloading of delicate materials -
inner lining for floor tiles and so on.
PROCESS OF
MANUFACTURE
Process
Stages/operations and Output
Intermediate Product
1. Purchase of curled
coir from South India.
·
Seasoning of rope bundles left in shaded godown rope for 2.5
to 3 months or matured in drying chambers
DRY AND MATURED CURLED
ROPE
2. Lamination -
formation
Ropes decurled on untwisting
machines
Open
fibre (each fibre becomes spring) passed through sheet machine to
obtain lamination of desired width
Natural latex rubber blended with
chemicals sprayed on the sheet before it enters the sheet plant
chamber
Latex
rubber compound sprayed on reverse at the other end of the
chamber
Lamination
cut by Rotary Cutting machine to roughly required length
required number of laminations to achieve desired density for
each thickness joined together and hand pressed
UNPRESED
BLOCKS
3. Pressing
pressed in Hydraulic press
to required thickness under pressure and heat
PRESSED
BLOCKS
4. Curing
Blocks in trolley trays
subjected to vulcanising operation for 45 to 60 minutes. Rubber
spray gets cured and this develops spring effect
CURED
BLOCKS
5. CARPET
UNDER LAYS made of selected springs of coir fibre, carpet underlay are manufactured in thickness
of 10 mm to 25 mm with Hessian cloth backing to provide smooth
surface. Spread underneath wall to wall carpet or living room
carpets, these add to the deep pile comfort and protect the carpet
from moths and vermin. These help reducing noise of stamping feet
and squeaking shoes and in case of falling of delicate articles save
breakage. Life of carpet is thereby enhanced several
times.
Blocks side trimmed to exact dimensions on cutting tables
applying Band saw cutting machine
UNCOVERED
MATTRESS
FINISHING
·
Foam pasting - A layer of 6 to 20 mm polyurethane foam pasted
for extra smoothness of the surface
6. Covering
·
Mattresses are covered with Handloom tapestry/other
furnishing cloth of attractive designs, texture, quilted
cloth, etc.
FINISHED
MATTRESS
RUBBERISED COIR PLANT
PRODUCTION PROCESS
Drying chamber - Curled coir is dried at 80-90 oC for 3 to 5
days. In case of natural seasoning, bundles are left for 2.5 to 3
months
Untwisting - Rope is untwisted and converted to open fibre. Each
fibre comes out as a spring.
Sheet machine - Consists of picker, fleece former, conveyors for
lamination, rollers and the main chamber.
Open curled fibre on purpose is fed
through the conveyor, which is lifted, to the fleece former under
air pressure of the blower. The density of the sheet to be achieved
is adjusted through the roller and the fleece former segregates
interlocks and makes lamination of curled fibre
automatically.
Latex compound spray is done on
lamination as it enters the main chamber and on the other side of
the chamber the lamination reverses, where latex compound is again
sprayed and the lamination renters the chamber. This is the main
operation of the Rubberised Coir manufacturing
process.
Rotary cutting - Circular knife revolving at a high speed is machine
provided at the other end of the main chamber, where lamination is
cut to required lengths.
Weighing - For checking density as per the product machine
requirements.
Hydraulic press - Blocks are subjected to pressing by hydraulic press to
give final thickness. Moulded items are pressed in moulds made of
wood.
Cutting table - Band saw cutting machine having a moving table trims
the product to required length and width.
Vulcanising - Products are loaded on trolley trays of the chamber
and are subjected to curing at 120 oC.
Testing equipment - For quality assurance, products are subjected
to:
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