Your customers
- Mattress makers
- Sofa and furniture makers
- Foam and upholstery dealers
- Auto seat, footwear and bag makers
- Packaging and technical foam buyers
- Rebonded foam makers (trim)
Chemicals, plastics and rubber · Makers and factories
MatruOS for a PU foam block plant
Set up the way a PU foam block plant runs: sale of flexible PU foam by weight: whole blocks, cut sheets and rolls in density grades 18 to 40, HR and memory foam, rebonded foam from scrap, and trim sold to bonders; some plants also do job cutting. Routines, workflows, registers, licences and an AI team that knows the work are ready when you sign up.
Ready when you sign up
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What this solves
What a PU foam block plant deals with today, and what MatruOS sets up for it
Today
TDI and polyol prices move every month and the owner buys at the wrong time or runs out mid-week. Rate list lags chemical cost, so a month of sales goes at old rates.
In MatruOS
MatruOS sets up 14 routines, 3 workflows, 4 registers and 15 licences for a PU foam block plant, with an AI team that reads your own records and prepares the work.
What changes
The right person is reminded at the right time, approvals wait for whoever decides, and every licence has a renewal reminder. Anything that sends, pays, signs, files or deletes waits for a person's approval.
Where you sit
MatruOS starts from how your business earns
Who you sell to, who you buy from, how credit moves and where you sit in the chain decide how your screens, reminders and reports are set up.
- TDI and polyol importer
- foam slabstock plant
- mattress, sofa and auto seat makers
- dealer or showroom
- household
Your suppliers
- TDI importers and distributors
- Polyol importers and distributors
- Silicone, amine and tin catalyst suppliers
- Methylene chloride dealers
- Calcium carbonate millers
- MDI dealers (rebond binder)
- Stretch film, poly bag and HDPE wrap suppliers
Credit and cash
Chemicals: advance or 7-30 days, tanker loads against LC or advance; buyers: mattress makers and dealers 15-45 days, institutions 45-60 days; trim buyers cash
Chemical stock 2-4 weeks (lumpy, bought on price dips); foam itself turns in 3-7 days after curing; receivables 30-45 days; price list revised every month with TDI and polyol
Your screens use your words
CustomerPartyItemFoam gradeInvoiceBillBatchPourproductBlock
How it works
How MatruOS is set up for a PU foam block plant
Set-up takes a few minutes. After that, you change only what is different in your business.
- Describe the business in one lineFor example "PU foam block plant", typed when you sign up.
- Recognised as a PU foam block plantRoutines, workflows, registers, items, licences and the AI team for this trade are set up for you.
- Bring your dataCustomers, items and balances come across from Zoho Books, Vyapar, Excel and others. For Tally, our team helps you move the data while Tally import is checked on the live app.
- Approve and runThe AI team prepares the routine work. A person approves anything that sends, pays, signs, files or deletes.
Your AI team
What the AI team does for a PU foam block plant
Each job goes to a member of your AI team. It reads your own records and prepares the work. Anything that sends, pays, signs, files or deletes waits for a person's approval.
Lists today's pours by grade, size and colour from open orders and stock gaps, works out the chemical quantities from the grade formulas, checks them against store stock and schedules curing slots and core-temperature checks for each block
Works it out and shows you
Works out days of TDI, polyol and additive cover at the current pour rate, compares this week's quotes with past buys, and drafts purchase orders that keep TDI under the storage threshold
Asks you before sending and paying
Ages each party's dues, drafts WhatsApp statements and reminders, and lists parties to hold dispatch for
Asks you before sending
Recomputes chemical cost per kg for each foam grade at current prices, proposes the new per-kg rate list, and drafts the message to parties
Asks you before sending
Reconciles chemicals issued with foam produced and trim generated by grade, shift and cutter, and flags losses above the norm
Works it out and shows you
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How you run
Your routines, already on a timetable
Each routine has a time, a person and its steps with the checks that matter. MatruOS reminds the right person and keeps the record. Open one to see its steps.
Every day
7:30 amMorning chemical store and tank check
- 1Dip or read TDI and polyol tank and drum levels
- 2TDI store temperature between 18 and 30 °C (TDI freezes at 4-10 °C)
- 3Drum lids closed and no leak or crust at the TDI store
- 4Spill kit and decontaminant at hand
8:30 amDaily pour plan and formula sheet
- 1List orders and stock gaps by grade, block size and colour
- 2Set the formula per grade: water, TDI index, catalysts for today's temperature
- 3Total the chemicals needed against the store stock
9:30 amFoaming run and pour sheet
- 1Chemical temperature before mixing 20-25 °C
- 2Weigh each chemical to the formula; TDI within ±0.5%
- 3Note cream and rise time for each pour
- 4Fill the pour sheet and number each block
11:00 amCured block sampling and lab test
- 1Take a sample from each block cured 24 hours or more
- 2Density within ±5% of grade
- 3Indentation hardness (ILD) to grade card
- 4Pass the block or hold it as second grade
2:00 pmCuring area core temperature watch
- 1Probe core temperature of each block poured today; alarm above 170 °C
- 2Fresh blocks kept 1 m apart and away from walls and finished stock
- 3Move any smoking or scorching block outside at once
6:00 pmDaily cutting output and trim weighing
- 1Weigh good sheets and trim from each block
- 2Sheet thickness tolerance ±2 mm
- 3Bag trim for the rebonding press or the trim buyer
8:00 pmNight curing and fire round before closing
- 1Second core temperature check on today's blocks
- 2Extinguishers, hydrant and fire alarm working; exits clear
- 3Mains off in the cutting hall; curing area lit and watched
Every week
Mon 10:30 amWeekly TDI and polyol price and reorder check
- 1Collect this week's TDI, polyol and MDI quotes from distributors
- 2Days of chemical cover at the current pour rate
- 3Decide buy now or wait; keep TDI below the 10 tonne MSIHC storage threshold unless notified
Sat 11:00 amWeekly party dues and dispatch hold list
- 1Age each party's dues; send statements on WhatsApp
- 2List parties over 45 days for dispatch hold
- 3Match cheques and UPI received to bills
Every month
1stMonthly per-kg price list revision
- 1Work out the chemical cost per kg for each grade at this month's TDI and polyol prices
- 2Add conversion cost and margin; compare with nearby plants' rates
- 3Send the new rate list to parties after approval
5thMonthly chemical-to-foam reconciliation
- 1Total chemicals used from pour sheets against store issues
- 2Foam kg out against chemical kg in; loss above 6% flagged by grade and shift
- 3Trim % per block from the cutting register; above 12% flagged
Every year
MarYearly licences and safety renewals
- 1Renew factory licence, fire NOC and pollution consent where due
- 2File the hazardous waste annual return (Form 4) by 30 June
- 3Fire mock drill and TDI spill drill with all shifts
- 4Renew fire and stock insurance at declared stock value
Workflows
Each stage goes to the person who handles it
Work passes stage by stage to the right person. Stages marked for approval wait for the person who decides.
Party order to payment
- 1Order booked with grade and kg
- 2Rate and credit approvedNeeds approval
- 3Poured or picked from stock
- 4Cured and passed QC
- 5Cut and weighed
- 6Billed and e-way bill made
- 7Payment received
Chemical purchase and receipt
- 1Quotes collected
- 2Purchase approvedNeeds approval
- 3Advance or LC paid
- 4Received and weighed with COA
- 5Trial pour passed
Empty TDI drum and residue disposal
- 1Drums decontaminated and counted
- 2Disposal approvedNeeds approval
- 3Handed to authorised recycler
Registers and SOPs
Your registers and standards
Registers hold the fields this trade records. SOPs carry the steps and checks, so work is done the same way every time.
Pour sheet (foaming batch log)
Block curing and stock register
Cutting and trim register
Party order and dispatch book
TDI handling and pouring
Pour foam of the right grade without exposing workers to TDI
Block curing and fire safety
Stop self-heating blocks from starting a fire
Foam grade testing
Sell each block at the grade it really is
Items and licences
Your first bill is right, and no licence lapses
Starter items arrive with unit, HSN and GST rate. The registrations this business usually needs are listed with a reminder before each one expires.
| Item | HSN | GST |
|---|---|---|
| PU foam block density 18 | 3921 | 18% |
| PU foam block density 23 | 3921 | 18% |
| PU foam block density 28 | 3921 | 18% |
| PU foam block density 32 | 3921 | 18% |
| PU foam block density 40 | 3921 | 18% |
| High-resilience (HR) foam density 40 | 3921 | 18% |
| Memory (viscoelastic) foam density 50 | 3921 | 18% |
| PU foam sheet cut to size | 3921 | 18% |
| Rebonded foam block density 80-120 | 3921 | 18% |
| Foam trim and skin scrap | 3915 | 18% |
| Job cutting of customer blocks | 998898 | 18% |
- GST registration
- Udyam (MSME) registration
- Factory licence
- Pollution consent (CTO)
- Fire NOC
- Hazardous waste authorisation
- Trade licence
- Insurance policy
- PF registration (EPFO)If it applies
- ESI registration (ESIC)If it applies
- BIS licence (ISI mark)If it applies
- EPR registration for plastic packagingIf it applies
- TrademarkIf it applies
- Import Export Code (IEC)If it applies
- Boiler registration and certificateIf it applies
Your people
The people who run it, each with their own login
Each person sees the screens and reminders for the work they do.
Owner (proprietor)Buys TDI and polyol, sets the monthly per-kg price list, gives credit to parties, handles licences and the bank.
Foam masterSets the formula for each grade, runs the pour, watches rise and exotherm, signs the pour sheet.
Foaming crewWeigh and charge chemicals, clean the mixer and moulds, demould and shift blocks to curing.
Quality checkerCuts samples from cured blocks, tests density and hardness, passes or holds blocks.
Cutting operatorCuts blocks into sheets and rolls, weighs trim, runs the rebonding press.
Store and dispatch in-chargeKeeps chemical and block stock, loads trucks, makes bills and e-way bills.
Accountant (munim)Keeps party ledgers, follows up dues, prepares GST returns.
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Not covered yet
- Sending messages, bills and reminders on WhatsApp from MatruOS is not live yet. Today they go by link, QR code or email, and from your own phone in one tap.
- Live bank and UPI feeds are not connected yet. Upload a bank statement and MatruOS reads it into payments for you to confirm.
Questions people ask
How long does it take to set up MatruOS for a PU foam block plant?
Type one line about your business when you sign up, for example "PU foam block plant". MatruOS picks this business type and sets up everything on this page in a few minutes. You then get a 7-day free trial, no card needed.
Do I have to type all of this in?
No. The routines, workflows, registers, items, licences and AI team on this page arrive already set up. You change what is different in your business, and bring your customers, items and balances from Zoho Books, Vyapar, Excel and others, with our team's help for Tally data.
Can I change the routines and workflows?
Yes. Every routine, workflow, register and SOP is yours to rename, retime, switch off or add to. MatruOS keeps the rest of the system in step with your changes.
What does the AI team do without asking me?
It runs routine checks and prepares drafts. Anything that sends, pays, signs, files or deletes waits for a person's approval. The one exception you can choose is payment reminders, which go out on their own once you have checked them and switched them on.
Chemicals, plastics and rubber
Other makers and factories in chemicals, plastics and rubber
Run a PU foam block plant on one system Set up for your trade when you sign up.
Describe your business once. MatruOS sets up your apps, brings in your data and puts Muni and the AI team to work, with your approval on every step that matters. 7-day free trial, no card needed.
See plans and what each includes