Mouka Foam Mattress Factory

We visited the Mouka Foam Factory on Tuesday the 14th of October. The visit was to pick 6 of the mattresses that will go in apartments in our new Mission Building. One of our Ward Members is the Sales Coordinator for the entire operation. This is the largest mattress factory in Nigeria. They produce 11 Billion Naira worth of mattresses a year. We see Mouka Foam Mattresses everywhere. Every missionary apartment is equipped with these mattresses. Our apartment is equipped with them as well.
This young man is standing next to a stack of completed mattresses.


This spring affair is the insides of the mattresses we chose. The blocks of foam support the springs
The entire assembly is then covered in foam thicker than the blocks you see between the springs. After that, the foam-spring "sandwich" is covered and sewn with the finished cover you see in the first picture. Most Mouka Foam Mattresses are just foam. They make different firmnesses of foam and you pick your mattress by the firmness or softness. The colors of the foam indicate soft or firm. There is a wonderful machine that cuts the slabs of foam in the next picture from huge blocks of foam.


These "slabs" of foam have just been cut by the amazing machine. We saw no heat. We saw no shavings from the cutting process, but these slabs came from blocks of foam more than 6' tall. The next picture shows stacks of raw foam slabs before it is covered. The covers are stitched on by a sewing machine mounted at an angle and at the exact height of the platform the foam lays on while being covered and sewn. The sewing machine operator doesn't have to bend or move into any uncomfortable positions to sew the mattress covers on. The mattress turns on a table to bring the foam and the cover to the sewing machine and the operator. It is cool.

The stacks of raw foam mattress slabs are just waiting to move to the next station in the process. The factory was laid out with fire safety and physical safety of the workers in mind. Every section could be shut off in case of fire. Every worker we saw who worked in an area of chemical reactions or dust wore masks like the one to the left.






This last picture shows blocks of foam that have not yet been cut into the thicknesses for mattresses. We saw mattresses made from this foam that were as thick as 18" and as thin as 6". Linda is not so sure we will receive the size and type of mattress we chose. We will update you after we move into the new Mission Building.