Soft Foam Home for Kids – Trusted OEM/ODM Partner Since 2013

Production Process

Our production process follows strict high standards, with each step carefully controlled to ensure that our sofas and soft play products achieve excellence in safety, comfort, and durability. Below is a detailed breakdown of our process.
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Meet Our Factory Director

Behind every soft module we make is a leader who truly understands the responsibility ofmaking products for children.Mr. Hu, our Factory Director and co-founder, has been in factory management since 2005and has spent the past 16 years specializing in soft foam furniture for kids.Known for his rigorous standards and calm discipline, Mr. Hu ensures our workshop runs withprecision, consistency, and above all - safety.

We don't just build products-we build safe spaces for families.

Mr. Hu Factory Director and co-founder

Manufacturing Workflow

01step

Preparation of Materials for Examination

Purpose:

Ensure design drawings, styles, fabrics, trims, and foam types are fully aligned with inventory.

Key Actions:

  • Sample/Drawing Confirmation
  • Fabric Order
  • Trimming Arrival Inspection
  • Foam Specification Preparation

Responsibilities:

PMC + Development Department + Warehouse

02step

Fabric Cutting (Automatic/manual)

Purpose:

Cut fabric according to pattern drawings

Equipment and Tools:

Automatic fabric cutting machine + manual electric shears.

Requirements:

Precisely allow for seam allowances at joints, numbering and categorizing.

03step

Sewing & Fabric Assembly

Purpose:

Sewing fabric into modular pieces to create a removable or fixed cover.

Process:

  • Jointing
  • Sewing
  • Corner wrapping
  • Zip/Velcro application

Key Points:

Even stitching, neat edge banding, and accurate logo placement

04step

Foam Cutting (CNC cutting)

Purpose:

Cut large foam sheets into specific sizes and shapes according to product structural drawings.

Key Equipment:

CNC foam cutting machine, high-speed cutter, foam stacking system.

Precision Requirements:

±2mm, burr-free edges

Key Points:

Cut the foam one week before shipment to ensure freshness

05step

Foam Insertion & Shaping

Purpose:

Assemble the foam and fabric cover and complete the shaping process.

Key Actions:

Press the foam into the fabric bag with manual pressure.

Locally adjust the bend and align the seam allowance.

Inspection Points:

Full appearance, natural curves, and no bubbles or wrinkles.

06step

Compression Packing

Purpose:

Use vacuum compression or automated compression systems to reduce volume and facilitate export.

Process:

  • Fold
  • Pack
  • Vacuum evacuation
  • Heat sealing

Volume reduction: 60%-70%

Key Point:

Start compression 3-5 days before shipping to minimize compression time. The shorter the compression time, the better the rebound effect.

07step

Label & Packing

Purpose:

Apply barcodes and warning labels according to customer requirements and perform standard packaging.

Requirements:

Apply barcodes by SKU and batch number.

Package items according to the packaging diagram (multiple items must be separated).

Standard:

Outer box must be waterproof/compression-resistant, with smooth sealing tape and a neat appearance.

08step

Warehousing

Purpose:

Orderly storage of finished goods, supporting stocking, container consolidation, and customer-specified shipping plans.

System Operation:

  • ERP Registration
  • Warehouse Partitioning
  • Schedule shipments by delivery date.

Key Points:

Supports mixed SKU loading, direct shipping, and overseas warehouse delivery.

09step

Loading & Shipping

Purpose:

Ship completed orders according to customer specifications to Ningbo Port or other warehouses.

Methods supported:

  • FULL (40HQ)
  • LCL (mixed container load)
  • Palletizing + film wrapping + loading

Key Points:

Timeline control + simultaneous preparation of customs clearance documents

Key Equipment

Cloth Inspection Machine

It is used to detect width, color difference, weaving defects and other problems of large rolls of fabric before they are put on the production line to ensure the fabric qualification rate.

Industrial Sewing Machines

Sew product parts such as coats, tents, pillows, etc., supporting various stitches and sewing styles.

Fabric Spreading Machine

The entire roll of fabric is spread out on the cutting table, automatically aligned and stacked, ready for automatic cutting.

Automatic Fabric Cutting Machine

Automatically cut fabrics with high precision according to the pattern drawing to improve efficiency and reduce cutting errors.

Vacuum Compression Machine

Small sofas, soft toys, etc. can be compressed by vacuuming to save up to 75% of their volume.

Compression Roller Machine

Used for automatic roller compression packaging of large-area flat products such as gaming sofas and ball pool mats.

Heat Sealing Machine

Heat seal the compression bag opening to ensure stable sealing and no bulging during transportation

Auto Packaging Line

It realizes the automated packaging process from bagging, sealing, labeling to cartoning, which is suitable for batch shipment of products.

Barcode Printing & Labeling System

Print SKU barcodes, customer-specific codes, logistics labels, etc. to ensure accurate shipment.

Smart Compression Packaging System

Save 60% Volume. Cut Shipping Costs. Boost Efficiency.

Why is compression packaging important?

Children's soft goods are bulky, lightweight, and yet take up space, making them a challenge in cross-border shipping. Tenderplayful, leveraging years of technological expertise, has developed a highly efficient compression and packaging system that helps customers save 75-82% of shipping volume without sacrificing product quality, significantly reducing unit logistics costs.

How do we achieve compression?

A variety of compression methods are available to suit different product structures:

Vacuum compression:Suitable for children's sofas, small soft toys, etc.

Roller compression:Suitable for modular sofas, soft toys, ball pool mats, etc.

Compressed packaging format

High-density vacuum-packed PE bags ensure neat and controlled packaging.

Automatic sealing ensures no bulging during transportation.

The packaging is labeled "Please wait 48 hours" for end-user convenience.

Improved loading efficiency

Taking a 40HQ container as an example, traditional sofa products can be loaded with about 120-150 pieces, but after Tenderplayful compression, it can be loaded with more than 200 pieces, greatly improving the profit margin of a single container.

User safety + customer experience

Compressed products recover within 48 hours after unpacking, with a rebound rate of over 95%. We include a restoration card and unpacking instructions with each product to ensure easy use for end customers.

Luca

Customers from Germany

4 times more than our previous supplier!

Frequently Asked Questions

  • Customization Process
    The customization process involves consultation to discuss requirements, followed by design confirmation and pricing. A sample is created for approval, and once confirmed, a contract is signed with payment terms. Production begins with updates, and quality checks ensure products meet standards. Products are safely delivered through trusted logistics, and after-sales support is provided for any issues. This process ensures a smooth, transparent experience for customers.
  • Design & Samples
    Customers can provide their own designs or request assistance from our design team. We offer samples for approval, which are generally charged, with the fee partially credited if a bulk order is confirmed. Design modifications are allowed during the process. Sample delivery typically takes 7-10 business days.
  • Delivery & Shipping
    Customized products typically have a delivery time of 15 to 30 business days, depending on complexity and quantity. To ensure on-time delivery, we provide real-time updates and address potential delays proactively. We use professional packaging and collaborate with trusted logistics companies to ensure the products are safely delivered without damage.
  • Quality Assurance
    We guarantee the quality of customized products through strict adherence to international standards and thorough quality checks at every production stage. If any quality issues arise, we offer after-sales services such as replacements or repairs. Our quality inspection process includes material testing and functionality checks, and we ensure product durability by using high-quality materials and providing care instructions.
  • Custom Styles, Fabrics, and Foam
    We offer a variety of custom styles, fabrics, and foam options to meet different needs. Customers can choose from classic or personalized designs, select fabric options like upholstery, leather, or eco-friendly materials, and customize colors and textures. For foam, we provide high-density, low-density, and memory foam options to ensure comfort and support. Each customization is carefully designed to align with both functional and aesthetic requirements.

Logistics Efficiency | From Factory to the World

Proximity to Ningbo Port + Smart Packaging = Fast, Cost-Efficient Global Shipping

Geographical Advantage | Shipping close to Ningbo Port

Our factory is located in Ninghai, eastern China, just a 1.5-hour drive from the world-class container hub of Ningbo Port, offering convenient access to land-port intermodal transport.

Fast dispatch, same-day container pickup, and flexible arrangements for LCL/FCL shipments are our daily rhythm of efficiency.

Flexible and diverse shipping methods

We support a variety of shipping options to meet diverse customer needs:

  • Full Container Load (FCL) / Less Than Container Load (LCL)
  • Multiple SKU palletizing
  • Connect with overseas warehouses or direct shipping platforms for transit

Compression packaging helps optimize logistics costs

Combined with our compression packaging system, the actual loading capacity of each container can be increased by up to 4-5 times, effectively reducing unit logistics costs and helping you gain higher profit margins in global channel competition.

Delivery time and tracking management

Daily production scheduling + fast loading responseArrival at port within 2 hours

Provide complete delivery documentation, including loading diagrams, packing lists, and tracking numbers

Capturing Moments of Trust, Connecting Clients Worldwide

At Tender Playful, every handshake, every visit, and every photo tells a story — a story of mutual trust, shared values, and lasting partnerships. From Europe to North America, Asia to Oceania, we’ve had the honor of welcoming clients from all over the world to our factory. These captured moments are more than just pictures — they are the proof of genuine collaboration and growing friendships across borders.
Please send your message to us
We provide flexible customized production of unconventional products. Contact us for a quick quote.
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