Quality & Process

Quality is not
inspected in.
It is manufactured in.

At Madhav Cotex, quality begins at the formulation stage and is maintained by the precision of the Hennecke line through to QC testing before every despatch.

Manufacturing process

From raw material
to despatch.

01

Raw Material

Polyols, isocyanates and additives sourced to specification. Incoming material verified before entering production.

Chemical storage area with sealed containers
02

Formulation

Recipe engineered per grade. TDI index, water ratio and catalyst balance set to exact specification for the target density and performance.

Hennecke machine control panel showing production parameters
03

Continuous Pour

Hennecke line executes the pour with precision-controlled pump rates, temperatures and pressures. Inline density monitoring throughout.

White foam rising and expanding on conveyor belt
04

Curing & Cutting

Blocks cure to full properties before cutting. Cutting to standard lengths or customer specification.

Fresh foam blocks standing upright in curing area
05

QC & Despatch

Every batch tested for density, hardness and compression set. Passed batches despatched. Failed batches quarantined and reviewed.

QC technician testing foam sample with precision equipment
"The same grade, ordered six months apart, will perform identically."

The Madhav Cotex consistency guarantee

The Hennecke Advantage

Why continuous line
manufacturing matters.

Most foam manufacturers in India use box-pour machines — a manual, batch-based process where mix quality varies with every pour.

Madhav Cotex runs a Hennecke continuous slabstock line. Chemical streams are metered by precision pumps at controlled rates, temperatures and pressures — every second of the run.

The result is a foam block where density, cell structure and mechanical properties are consistent from the first centimetre to the last.

For buyers: predictable cutting yields, fewer rejects, and end products that perform as specified — not just sometimes, but every time.

Hennecke continuous foam production line stretching into distance
Testing

What we test.

Every batch undergoes systematic QC testing before despatch. Our testing regime covers all parameters that determine end-product performance.

Parameter Method Why it matters
Density kg/m³ measurement Core specification — confirms the foam grade delivered matches what was ordered
Hardness (ILD) Indentation Load Deflection at 25% & 65% Determines comfort feel and support characteristics for end-use applications
Compression Set % deformation after sustained load Predicts long-term durability — how well the foam recovers after extended use
Cell Structure Visual and tactile assessment Consistency of foam microstructure — affects breathability and surface quality
Dimensional Check Physical measurement Block dimensions confirmed to specification for cutting yield accuracy

Want to understand how our
process applies to your application?

Talk to Our Technical Team