It’s every child’s dream to jump into a pool of foam. I didn’t get to do it, but the experience I had was close enough.

Together with other people from the press, I was recently invited to visit the 60,00 square-meter factory of Uratex in Muntinlupa City. Uratex is the leading foam manufacturer in the Philippines. They started making foam in 1968 and have since grown and expanded. Today, Uratex’s world-class foam products—from really comfortable mattresses and pillows, to kitchen sponges and car seats—have permeated almost every Filipino home and have thus become a successful local brand.

The plant tour was especially interesting as they showed us how they made foam. It was, in a word, magic.

This is their research and development department. I know this because they’re wearing stereotypical pristine white lab coats. Here they formulate the specific foam mixtures to create specific foam products. I never thought foam was this complicated.

Here they burn the foam to test its flammability (or lack thereof). It’s important because a burning bed or pillow in your house is simply unacceptable. In another station they pull foam apart to test its strength. One girl’s job is to bounce a metal ball all day to test the foam’s “bounciness.” They’re serious about their foam.

After getting the perfect foam formula, they proceed to create the foam. And it all starts out in liquid form. The Hennecke–the foam-making machine they imported from Germany–is the source of everything. Streams of chemicals are sprayed using computer controlled metering pumps on a paper-covered conveyor belt. The smell is awesome, like permanent marker and candy.

As the belt and the paper move along the length of the machine, the liquid spreads and forms into a thin layer. Through an exothermic process, the less than one centimeter of liquid slowly rises as it goes through the machine. And this is the magic part–in less than two minutes all that turns into this…

A warm block of foam about a meter high emerges at the end of the line. It’s already safe to touch, but on the surface it’s still a bit moist.

The foam is then cut into 30-meter blocks for easy handling. At this point the outside of the foam block is already dry, but the inside is still warm and wet. The foam, i mean.

A giant crane then picks up the 30-meter block of foam and lays it down in a warehouse for curing. The foam block sits there for 24 hours until it cools down. After that they proceed to cutting the foam into the specific product it was designed to be. It can become a mattress,  a piece of kitchen sponge, or even the 1mm foam disk you see inside a hard drive. Uratex makes those as well.

Foam! They make bra padding too. So the next time you see a bra, imagine that a worker at Uratex had, at one point, his hands all over your underwear.