INTRODUCTION
Originally, foam rubber was made from natural latex, a white sap produced from rubber trees. As early as 500B.C Mayans and Aztecs used this latex fro waterproofing purposes and also heated it to make toy balls. During the early 1900s, the first patent for synthetic rubber was granted and several decades later a process for foaming latex was invented. After World War II, styrene-butad
iene rubber replaced the natural foam. Today, polyurethane is the most commonly used materials for foam products. Solid foam is formed when gas is blown through solidifying plastic. Depending on its ability to retain original shape after compression, solid foam can be classified as either flexible or rigid. Polyurethane foam is the most widely used flexible foamed plastic, being used for thermal insulation and packaging materials, cushions, bed mattresses, carpet backings and resilient floor coverings. The three main raw materials for the production of the flexible polyurethane foam are POLYOL TDI and WATER, The water is the essential element for life and it is also the reagent the allows the foam to expand and to rise. The raw materials are accurately conditioned and the different components are carried to a variable temperature between 200C and 250C, that is the best processing temperature. The reaction (Polymerization reaction) takes place in 1/3 minutes; during this time the foam block reaches the fixed dimensions. When the foam blocks gets out of the tunnel it is cut into variable length boards that are laid on the maturation system. During the 72 hours after the production process, the polyurethane reaction ends and the blocks are stored in warehouses. After that, the product can follow two different paths: it can be sold as a rough block or it can be brought in to the cutting division of the company. The Cutting unit makes use of high-tech machines and equipments. Coritrolled by skilled workers, These particular machines are able to offer reliable and adequate answers to the different market demands. Besides that, the company produces not only polyurethane foams, but cuts them in different shapes (such as mattresses, cushions and pillows )and helps its customers to find the best solutions for their problems, accompanying them towards the fulfillment of their projects. The company can make flexible polyurethane foam for many different kinds of furniture manufactures in the furniture and upholstery industry for local market. As the first step in the convert6ing process, it can also offer slab stocks that customers convert themselves. The customer specifies the block size, thereby efficiently minimizing trim foam loss. Theses products are mainly used by the up holster, furniture, and mattress and packaging industries. Plates and sheets are mainly used in flat upholstery and offer customers who have their own equipment a cheap alternative to ready-made, cut-to-size pieces. Untrimmed foam plates and sheets can be cut as thin as 2 mm horizontally from the foam block. The company can provide individual plates as well as entire slab stocks cut into plates of various thicknesses. Customers can specify the length of the panels and sheets they require. There are four polyurethane foam manufactures in Ethiopia; Rianbo, Royal , Kaangaroo. Which also acquired Addis Ababa foam in the near past, and lastly Ethio-foam ( Amaga trading) however, the major ones are the first three organizations. Royal Foam has been producing bedding mattresses with significant share in the domestic market.
