Our foam
Foam Density Grades Manufactured in Mauritius
We produce flexible polyurethane foam across a full range of densities, each engineered for specific applications. Explore our grades below to find the right match for your project.
Every Grade Made to Consistent Quality Standards
All foam manufactured at our Plaine Lauzun factory is tested against Mauritius Standard Bureau benchmarks based on South African Bureau of Standards. Every grade is anti-fungal, anti-bacterial, anti-allergenic, odourless, tasteless, and completely non-toxic.
We produce foam in standard slab sizes (36″x75″, 42″x80″, 54″x75″, 60″x80″) and can accommodate thicknesses from 1/8 inch to over 30 inches.
STD Standard Foam
STD Standard Foam is our general-purpose flexible polyurethane foam, designed for light padding and basic upholstery. It provides a soft, reliable base for projects where high firmness is not required, and works well as a comfort layer when paired with denser grades underneath.
Specs: Standard density. Colour: Pink. Available in all standard slab sizes and custom dimensions. Lightweight with moderate resilience. Easy to cut and shape to any thickness.
Common uses: Armrest padding, light seat cushioning, secondary comfort layers in sofas and mattresses, headboards, decorative padding, and general-purpose applications where softness is the priority.
D18 Soft Foam
D18 Soft Foam is our lightest grade at approximately 18 kg/m³. It is highly flexible and used extensively outside traditional furniture applications. D18 is the go-to choice for packaging, insulation, and industrial use where lightweight cushioning and shock absorption are needed without added bulk.
Specs: Density ~18 kg/m³. Low load-bearing, not recommended as a primary seat cushion. Excellent shock absorption relative to weight. Available in thin sheets from 1/8 inch or thicker blocks depending on the application.
Common uses: Export packaging, quilting, luxury book binding, clothes padding, soundproofing panels, thermal insulation for walls and ceilings, protective lining for fragile goods, and industrial applications.
D21 Medium Foam
D21 Medium Foam is our mid-range all-rounder at approximately 21 kg/m³. It is the most commonly used foam for mattresses in Mauritius, offering a comfortable balance of softness and support for everyday sleeping surfaces and general cushioning. Colour-coded yellow across our range.
Specs: Density ~21 kg/m³. Colour: Yellow. Medium firmness with good resilience. Available in all standard slab sizes (36"x75", 42"x80", 54"x75", 60"x80") and custom dimensions. Durable under regular daily use.
Common uses: Foam mattresses (polycotton, luxury, and quilted finish), sofa back cushions, pillows, headrests, residential furniture padding, and any application needing a medium level of comfort for regular use.
D25 Firm Foam
D25 Firm Foam is our best-seller at approximately 25 kg/m³. It delivers superior firmness, resilience, and durability, and has passed Mauritius Standard Bureau testing based on South African Bureau of Standards. Colour-coded blue. Competitors' blue foam on the local market often measure as low as 22 kg/m³, while our D25 consistently delivers true 25 kg/m³ density.
Specs: Density ~25 kg/m³. Colour: Blue. MSB tested and certified. High firmness with excellent shape retention and long-term durability under repeated use. The most cost-effective grade for applications requiring both comfort and structural support.
Common uses: Furniture seat cushions, premium mattresses, car seat cushioning, commercial and office seating, restaurant chairs, sofa seat bases, and any application where firmness and consistent quality are the priority. The most popular grade among furniture manufacturers in Mauritius.
D30/D35 Foam
D30/D35 High Density Foam is our highest grade at 30 to 35 kg/m³, exclusively manufactured by Plyfoam in Mauritius. Produced for special orders, it can be customised to your exact specifications. We can make D30 softer for hotel beds or firmer for structural and institutional use. Also available in fire-retardant (FR) formulations.
Specs: Density 30-35 kg/m³. Colour: Grey. Not available from other local manufacturers. Custom firmness on request. FR formulations for commercial safety compliance. Manufactured to order with lead times depending on quantity.
Common uses: Hotel mattresses (custom firmness), hospital and institutional bedding, orthopaedic cushions, heavy-duty commercial seating, restaurant booths, and any environment where foam must maintain shape and support under prolonged intensive daily use.
Need a grade not listed here?
We also manufacture fire-retardant foam, high-resilience foam, and rebonded foam to order. Contact our team to discuss your specific requirements.
FAQ
Foam Grades & Specifications
Technical questions about our foam products, densities, and how to choose the right grade.
D21 (yellow) has a density of approximately 21 kg/m³ and is softer, making it ideal for mattresses and back cushions. D25 (blue) is denser at 25 kg/m³, providing more firmness and durability, which is why it is the preferred choice for furniture seat cushions and premium mattresses.
D30 and D35 are high-density grades that require specific manufacturing runs. They are exclusively produced by Plyfoam in Mauritius and are typically ordered by hotels, hospitals, and institutions that need custom firmness or fire-retardant properties.
As a general rule: D18 for packaging and insulation, D21 for mattresses and soft cushioning, D25 for furniture seats and durable bedding, D30/D35 for commercial and institutional use. Our team can advise further based on your specific project.
Yes, particularly with our D30/D35 range. We can adjust the firmness level during manufacturing to suit your application, for example making it softer for hotel guest beds or firmer for structural seating.
We produce foam in four standard slab sizes: 36"x75", 42"x80", 54"x75", and 60"x80". Custom dimensions are also available on request, and we can cut to any shape or thickness from 1/8 inch to over 30 inches.