Polyurethane foam is manufactured from two foaming machines installed by CANNON, Italy. These machines have carrousel installed to produce the foam in an efficient and cost effective method. The ratio changer on our machines enables us to provide various densities of the moulded foam simultaneously. We can achieve different hardness and are able to maintain very consistent supply of polyurethane foam with a narrow band of hardness variation.

Our manufacturing system enables us to achieve consistent quality. The process is TS16949 certified with a emphasis on continuous improvement, which is achieved by six sigma, kaizen and conscientious training of our personnel. The fully integrated manufacturing facility at Chakan is supplied with frames by our suppliers produced from high quality raw material procured directly by us. We have a fully conveyorized powder coating plant attached with a pretreatment line. This enables us to offer competitive pricing.The bus seats used in city buses can also be manufactured by us using blow molded shell constructions.

In order to achieve high standards in comfort, safety and styling, our state-of-the-art facility for design, development, prototyping and testing uses the latest technology, supported by a highly capable team of engineers. The computer-aided design and manufacturing facilities are equipped with the latest styling software, enabling the company's engineers to develop design concepts into solid models.

We have design and develop products that meet stringent international safety regulations. The facility's finite element analysis tools allow the simulation of test conditions so that destructive physical tests can be minimized.

Key capabilities include industrial design, craftsmanship, benchmarking, product design and development, simulation, pressure mapping equipment for comfort evaluation, trim engineering, prototyping, testing and validation facilities. A good example of our value engineering abilities is the cost reduction achieved by adding PU+PE foams in many seats.

Alpha Foam has a capability to design car seats and bus seats from scratch. The seat design can be validated as per international standards from ARAI or any other testing house.