Sandwich Pads
Sandwich PadsProduct Code: FV-Coirs-CFS
At Foam Villa, we provide high-quality coir and foam sandwich pads crafted using a balanced blend of rubberized coir and PU foam layers. Each combination is thoughtfully designed to meet a wide range of comfort, durability, and support requirements for various applications. Our goal is to deliver customized solutions that cater to individual preferences as well as specific market needs.
Popular Combinations Include:
- Coir Pads and Rebounded Foams:
This option features a firm coir layer on one side and a supportive rebounded foam layer on the other, offering a balanced feel with durability and dual-side usability.
Rubberized Coir Pads
Rubberized Coir PadsProduct Code: FV-CR-RCP
At Foam Villa, we specialize in manufacturing premium Natural Rubberized Coir Sheets and Pads. The process begins with coir fibers extracted from the outer husk of coconuts. These fibers are formed into sheets, sprayed with natural latex, oven-cured, and then pressed to create strong and durable rubberized coir pads. After processing, the pads are converted into cushions according to the exact size and specifications required by our customers. The quality and lifespan of coir cushions depend largely on their density and coir-latex composition.
Higher density and latex content enhance strength, support, and durability, while lower levels may lead to sagging and reduced cushion performance. In India, coir production plays a significant role as a traditional cottage industry, with coir-based products being exported to more than 100 countries.
Coir Cushions with Jute Support
Coir Cushions with Jute SupportProduct Code: FV-Coirs-JCC
We offer Jute-Packed Rubberized Coir Cushions, crafted to provide a perfect blend of natural comfort, durability, and orthopedic support. The process begins with high-quality coir fibers, which are obtained from the outer protective layer of the coconut husk. These naturally resilient fibers are cleaned, combed, and transformed into uniform sheets. The sheets are then sprayed with natural latex, which acts as a biodegradable bonding agent that increases strength without compromising the product’s eco-friendly nature. After latex application, the sheets are oven-cured to stabilize their structure and finally pressed into rubberized coir cushions in the required shapes and sizes.
Throughout production, the density and coir–latex composition are precisely controlled to meet specific customer needs and to match the intended orthopedic application. Once the rubberized coir pads are fully prepared, we convert them into customized cushions and wrap each one with a durable, breathable jute fabric. This jute layer not only enhances structural stability but also provides additional firmness, making the cushions more
Coir Cushions with Fabric Covers
Coir Cushions with Fabric Covers
Coir Cushions with Fabric Covers
Coir Cushions with Fabric CoversProduct Code: FV-Coirs-FCC
With years of dedicated experience in the coir and cushioning industry, we specialize in offering high-quality, fully fabricated coir cushions tailored to the exact needs of our customers.Our expertise allows us to produce cushions in a wide range of shapes, sizes, densities, and structural configurations, ensuring that every product meets both functional and aesthetic requirements. Whether a client needs simple rectangular pads, contoured orthopedic cushions, multilayered combinations, or specially engineered industrial inserts, we have the capability and technical knowledge to fabricate products that meet precise specifications.
We work with different grades of bare coir, selecting the appropriate fiber quality, density range, and latex composition based on the end application—be it comfort, support, durability, or specialized performance.
Bared Coir Cushions
Bared Coir CushionsProduct Code: FV-CR-CC
At Foam Villa, we specialize in offering premium Bared Rubberized Coir Cushions, designed to provide natural comfort, durability, and long-lasting support. Our coir cushions are made from high-quality coir fibers, which are extracted from the outer layer of the coconut husk. These fibers are first cleaned, combed, and transformed into uniform sheets. Each sheet is then sprayed with natural latex, which acts as a binding agent to enhance the fiber strength while keeping the product eco-friendly and completely chemical-free. After latex application, the sheets are carefully oven-cured and pressed to form rubberized coir pads with consistent density and resilience.
Once these pads are ready, they are converted into cushions according to the exact size and shape requirements of our customers. During production, the density and coir–latex composition are key factors that determine the quality, comfort, and lifespan of the cushion. Cushions with higher density and greater latex content provide superior firmness, long-term durability, and better structural support.
