Established 2018 · Bhopal, India

Largest rebonded Polyurethane (PU) foam player in India

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About Us

Sarva Foam Industries Limited (SFIL) is the largest rebonded Polyurethane (PU) Foam player in India (with an estimated market share of around 33% (FY 2026) and also the largest exporters of rebonded PU foam in India. With a diversified manufacturing base across West, North and South India, the company is positioned to cater to customers across the country. The company is a preferred supplier to one of the biggest foam company and preferred supply partner to leading mattress manufacturers in India. (SOURCE D&B)

DadriSilvassaKrishnagiri 1Krishnagiri 2

Zero carbon footprints: PU foam becomes foam pieces, then rebonded foam, and back to PU foam

2018 Established

4 Manufacturing units

15,500 MTPA

Manufacturing Process

Procurement and receipt of raw materials

Incoming materials are weighed, inspected and stored prior to use.

Sorting and grading

The foam trims/off cuts are sorted and graded according to grade, density density and colour so as to ensure consistency in the quality and characteristics of the finished product.

Shredding / crumbing

The sorted ttrims/off cuts are fed into shredding (crumbing) machines, which reduce them into small foam chips of uniform size suitable for the bonding process.

Blending with binder

The foam chips are conveyed to a mixing unit, where a metered quantity of polyurethane binder is applied and blended uniformly so that each chip is evenly coated. Colouring agents and additives are introduced at this stage where required.

Round linerebonded carpet underlay

Square linerebonded blocks and sheets

On the round line, the chips are moulded into cylindrical logs for the manufacture of carpet underlays

Moulding and steam bonding

Steam is introduced under controlled pressure to activate and cure the binder, thereby bonding the foam chips together into a solid mass.

On the square line, the chips are moulded into rectangular blocks for the manufacture of foam blocks and sheets

Curing and demoulding

The moulded logs and blocks are cured so as to allow the binder to set fully and to achieve desired physical properties, following which they are removed from the moulds.

Peeled into continuous sheets of the specified thickness

Laminated with a film / backing layer

Wound into rolls of rebonded PU foam carpet underlay

Cutting and conversion

The cured logs and blocks are converted into finished products.

Cut on horizontal and vertical cutting machines

Sheets and blocks of the required dimensions

Quality inspection and testing

The finished products are inspected and tested for key parameters such as density, thickness, dimensions and durability, so as to ensure conformity with the applicable specifications and customer requirements.

Packing and labelling

Products conforming to the required specifications are packed and labelled in accordance with customer and order requirements.

Storage and dispatch

The packed finished goods are stored in the manufacturing unit and thereafter dispatched to our customers in the domestic and international markets.

Our product range

Three Product Lines

Rebonded Foam Sheets

Rebonded foam sheets are available in varying thickness, density and grade to suit different end-use requirements. We offer a wide range of products such as memory foam, high resilience (“HR”) rebonded foam and fire-retardant foam.

Rebonded foam – High resilience (HR)

Features: High resilience Rebonded Foam Sheets offering support, durability and recovery under repeated use

Rebonded foam – Memory

Features: Rebonded Foam Sheets that conform to body contours, providing pressure-relieving comfort and support

Rebonded foam – Fire-retardant

Features: Rebonded Foam Sheets providing enhanced flame resistance

Rebonded foam – Regular

Features: Standard Rebonded Foam Sheets

Rebonded Foam Blocks

Rebonded Foam Blocks are available in varying thickness, density and grade to suit different end-use requirements.

FormatsBlocks, in varying thickness, density and grade

Rebonded Carpet Underlays

We manufacture various grades of Rebonded Carpet Underlays with varying thickness, density and backings.

Footlove 8 and Footlove 10

Thickness: 8 mm and 10 mm
Density: Medium
Backing: Double-sided non-woven
Application: Carpet flooring

Footbliss 9 and Footbliss 11

Thickness: 9 mm and 11 mm
Density: High
Backing: Stitch crepe paper & non-woven
Application: Carpet flooring

Footluxe 9 and Footluxe 11

Thickness: 9 mm and 11 mm
Density: Ultra-high
Backing: Stitch crepe paper & non-woven
Application: Carpet flooring

Footboard 3.5

Thickness: 3.5 mm
Density: Ultra-high
Backing: Non-woven & silver foil
Application: Acoustic underlay for wood & laminate floors; suitable for underfloor heating (not electric mats)

Opus 10

Thickness: 10 mm
Density: Ultra-high
Backing: Stitched paper & non-woven
Application: Carpet flooring

Footmate 8 and Footmate 10

Thickness: 8 mm and 10 mm
Density: High
Backing: Non-woven both sides
Application: Carpet flooring

Footwork 5.5 and Footwork 6.5

Thickness: 5.5 mm and 6.5 mm
Density: Extra-high
Backing: PE film both sides
Application: Carpet flooring

Manufacturing footprint

Four units across three states.

Manufacturing in Tamil Nadu, Uttar Pradesh and Dadra and Nagar Haveli, with the corporate office in Bhopal.

Head office Bhopal, Madhya Pradesh Manufacturing units Dadri, Uttar PradeshSilvassa, Dadra & Nagar HaveliKrishnagiri 1, Tamil NaduKrishnagiri 2, Tamil NaduBhopal, Madhya Pradesh (upcoming)

Map of India marking the manufacturing units at Dadri, Silvassa and Krishnagiri, and the corporate office in Bhopal

Our customers

Serving customers across India

Andhra PradeshAssamChhattisgarhGujaratHaryanaHimachal PradeshKarnatakaKeralaMadhya PradeshMaharashtraOdishaPunjabRajasthanTamil NaduTelanganaUttar PradeshWest BengalDadra and Nagar HaveliDelhi

Map of India with the states and union territories the Company supplies marked