“By moving foam cutting in-house, we gain full control over one of the most critical components in our mattresses, as well as having full control of foams used withing all our seating” said Graham Silman, Managing Director at Renray Healthcare. “This investment allows us to further improve our product quality, respond faster to customer demand, and reduce lead times—benefiting both our clients and the people they care for.”

Key Benefits of the New Foam Cutter Facility:

• Enhanced Quality Control: Direct oversight of foam specifications and cutting accuracy ensures consistent performance across all products.
• Faster Turnaround Times: Streamlined production processes reduce reliance on third-party suppliers, leading to quicker delivery schedules.
• Greater Flexibility: Enables the development of custom mattress solutions tailored to individual clinical needs.
• Cost Efficiency: Long-term cost savings will support continued investment in innovation and customer service.

This move is part of Renray Healthcare’s ongoing mission to deliver reliable, high-quality pressure care solutions that support the comfort, dignity, and health of patients and residents in care settings across the UK.

“For us, it’s not just about manufacturing mattresses—it’s about delivering better outcomes for vulnerable individuals,” added Graham. “This investment is another step in ensuring that our products continue to meet the highest standards in healthcare.”

Renray Healthcare invites care providers, NHS partners, and distributors to learn more about how this new capability will benefit their service and enhance patient care.

The two foam cutting machines are equipped with a circulating horizontal cutting knife to create the most precise of cuts and is said to be an ideal manufacturing tool for converting across a range of high-density foams. Many medical grade static mattresses consist of different density foams combined.

The latest Fecken Kirfel C67 technology means Renray Healthcare can produce over 3000 mattresses a week while seamlessly integrating into wider business programs.

Graham added: “The company is shaping its growth trajectory ready for expanding into new markets of foam conversion and these purchases alongside our machinery demonstrates our intent to grow our presence.

“Many of our existing customers are successfully growing their own businesses and we want to continue to support them on their journey, as a trusted partner for custom static mattress solutions.”