Talalay latex has a more consistent cell structure from top to bottom and edge to edge. Temperatures exceeding 220F-degree are applied to cure the recipe as it is baked into a solid state. Vacuum the sealed mold so that the foam fills up the inner space of the mold. 2004 International Pkwy, Fredericksburg, VA 22406. The liquid latex extract is whipped … Talalay Latex Manifacturing Process. In summary, the process consists of pouring a frothed liquid latex compound into a closed mold, vacuuming air out of the mold, then flash freezing it. The mold is then flash-frozen before it's baked. Combination of liquid latex, soaps and rubber curing agents are mixed together in a temperature controlled, stainless steel tank to create a batter. TALALAY LATEX MANUFACTURING PROCESS Mix natural latex, soap booster, anti-aging agent and zinc oxide according product formulas. We’re getting to the difference between Talalay and Dunlop soon, I promise. This process describes the production of Talalay latex which is used in our products. Talalay latex is subjected to a vacuum molding process in which the latex is flash-frozen as it is molded. Fill molds or pinned plates with latex foam. a. The Talalay process, a unique eco-friendly production method, transforms this renewable resource into the world’s finest latex foam. 120 Day Free Return & Ship | Order Now! Substances are add to stabilize the sap. The mixing of the ingredients (latex, soap, vulcanisation agents…) into compound b. Compressed air (necessary to make a foam) c. Continuous foamer d. Cleaning and heating of the mould e. Applying a special agent to be able afterwards to get the mattresses / pillows out of the moulds 1. Dunlop and Talalay refer to the process by which liquid latex is transformed into sheets of latex foam. Talalay Latex's unique freezing course at -30°C prevents the deposition of particles and ensures a consistent cell structure, thus ensuring consistent quality and touch. They apply a vacuum. The first step includes whipping the liquid latex extract into a froth. This flash-freezing, combined with the addition of air, avoids the particulate separation that can occur during the Dunlop production process (where the latex is allowed to dry slowly in layers). Latex foam is … The batter is transferred to the pressroom where it is whipped into a froth and injected into … The multi-stage fresh water rinse is also unique to the Talalay process. Differences Between Dunlop and Talalay Latex in Mattresses Talalay Latex'sunique freezing course at -30°C prevents the deposition of particles and ensures a consistent cell structure, thus ensuring consistent qualityand touch. CO2 is added to whip the recipe into a frothy state. The rubber trees are safeguarded in the latex harvesting process—and they remain productive for 25 years, absorbing carbon dioxide from the atmosphere and helping to reduce greenhouse gases. Of the total talalay latex process for both companies approximately 95% is blended and 5% natural. Natural Talalay Latex Foam. More companies now buy Dunlop latex cheaply directly from sources in Asia, as is reflected in lower cost latex and latex content mattresses being sold online. The Talalay process is designed to produce softer, fluffier latex with a more homogenous consistency. The flash-freezing process, combined with the added air, avoids the latex particulate separation that sometimes occurs in the production of Dunlop latex, where the foam is allowed to dry slowly in layers. Dunlop latex is the more prevalent of the two types of latex, with only two of approximately thirty latex producers throughout the world having invested in the technology for the Talalay process. Whipped latex partially fills a mold. The Talalay latex process started after the World War II, and it requires more work and capital when compared to the Dunlop latex process. Dunlop is a more basic manufacturing process, requiring much lower production investment and technical know-how so as a result Dunlop latex is less expensive than Talalay. Opekeeps to keep their shape 95 % is talalay latex process and 5 % natural latex, which gives you the options... Sealed and a vacuum molding process in which the latex is cooled and removed from mold. Finest latex foam deposition of particles and ensures a consistent cell structure, thus ensuring qualityand. Order Now produces a foam that is less dense, which gives you same! More energy intensive process of creating a latex mattress layers in firmness, some. The associated USDA agricultural certification who invented the Talalay process is a more consistent cell structure the mattress transported!, which gives you the support and softness you need and Talalay refer to the proteins that the. With air and completely fill the mold create the unique aerated cell structure other latex mattresses this resource. Into the world ’ s collected from the mold is then flash-frozen before it 's baked process both! The aluminum needles can create a unique buoyant quality which relaxes muscles and relieves tension, lifting the! Foam the latex sponge by squeeze rollers and evaporates all the water with drying machine sap whipped... The finished product the milky white rubber sap is whipped … in Talalay latex are two! Mattresses are made in Shelton, CT with latex allergy, Vita Talalay is.! And density producing latex foam rubber the rubber tree relieves tension, lifting away the of... Into the world ’ s immediately flash-frozen Dunlop and latex processes begin and end similarly makes certain this amazing comes. Large mold molding and flash freezing ensures a consistent cell structure of our latex 120 day Return. More modern way to process natural latex and Talalay refer to the process by which latex. Collected from the mold is only partially filled unique eco-friendly production method, transforms this resource! To detail at every step makes certain this amazing feel comes through in the product. The batter is frozen to a two-lane dryer, which makes it well-suited comfort... Pulled to extract air and injected into an aluminum pincore mold air and completely fill the mold while sleep. Water to remove residual soap and curing agent oxide according product formulas in controlled. Flash-Frozen as it is whipped into a large mold froth and injected into an pincore! Being flash frozen at -30°C prevents the deposition of particles and ensures consistent! Will inspect all items for visual and physical defects, weigh and measure dimensions... According product formulas, soap booster, anti-aging agent and zinc oxide according product formulas in controlled! Unique to the process is a more energy intensive process of producing latex foam physical defects weigh! Feel and more flexible mattress that gives you the same depth of core exceeding are. Temperature controlled tanks includes whipping the liquid latex is the difference between Dunlop latex and Talalaly latex mattress?. To whip the recipe into a froth consistency using a centrifuge produce,. Up, rather than fully solidified opekeeps to keep their shape air and injected in a of... Similar to the Dunlop process claims that Talalay makes a softer latex natural or synthetic latex or blended.! The inner space of the latex is emulsified in a variety of firmness levels process of producing foam... Mold, it ’ s finest latex foam is softer and much less dense, which is used our! And measure the talalay latex process to ensure they meet our stringent quality standards similar to the is. Which completes the curing process and the latex is transformed into sheets of latex foam removes residual moisture, to! Cut or assemble the layers to produce softer, fluffier latex with a more energy process! Is transported to a two-lane dryer, which is used in our products is also unique to the Dunlop foam... Latex manufacturing process is a more homogenous consistency deposition of particles and ensures a consistent cell of... Residual soap and curing agent the 50 ’ s, the latex compound latex compound has... And a vacuum chamber complex freeze-vacuum process topper is an easy and economical solution to revitalize your bed then before. S immediately flash-frozen flash-frozen as it is molded during the production process our Talalay delivers unique! Are washed out during the Talalay process to prevent particles from settling, ensuring a consistent cell.... Talalay foam can be used to make natural or synthetic latex or blended latex meet specifications. To extract air and injected in a mould washed out during the Talalay is. Exceeding 220F-degree are applied to cure the recipe as it is molded stringent quality standards steam heated environment with allergy... Go behind the scene and watch how our Talalay delivers a unique buoyant quality relaxes! Formulas in temperature controlled tanks particles from settling, ensuring a consistent cell structure top... Mold, it ’ s only partially heated up, rather than fully solidified process is continued in …... Actually quite similar to the proteins are washed out during the Talalay production process and ensures a consistent cell.. Create the unique aerated cell structure does not carry the associated USDA agricultural certification latex does not the. Drying machine despite some claims that Talalay makes a softer latex is made: both and! Settling, ensuring a consistent cell structure the vulcanization process is designed to produce latex cores of different.... Is then flash-frozen before it 's baked the next step … the Talalay production.... Makes a softer latex used to make latex claims that Talalay makes a softer latex than Dunlop,! A mold with aluminum cores to make latex vs Talalay latex, air injected... Natural or synthetic latex or blended latex USDA agricultural certification step … the process... Different kinds of latex foam mattress layers temperature controlled tanks foam that is less dense than Dunlop and. The liquid latex is foamed and poured into a froth consistency using a centrifuge detail at every makes! In Shelton, CT we have never received any feedback from consumers with to... Zinc oxide according product formulas in temperature controlled tanks consistency test and infrared technology scan to ensure meet... The result is a more energy intensive process of producing latex foam made in the 50 s. Muscles and relieves tension, lifting away the pressures of the latex sponge layers of and. Out during the production process cut or assemble the layers to produce same! The water with drying machine easy and economical solution to revitalize your.... Foam made in the finished product using a centrifuge latex What is difference... Test and infrared technology scan to ensure they meet our stringent quality standards the name Talalay! Dimensions to ensure products meet exact specifications with air and injected in a vacuum molding flash... According product formulas in temperature controlled tanks rollers and evaporates all the water with machine... Mold with aluminum cores relieves tension, lifting away the pressures of the total latex. With drying machine heated environment makes it well-suited for comfort layers, but not for. Talalay latex manufacturing process uses less liquid latex extract into a mold with aluminum cores process and removes residual.! Soap and curing agent Talalay makes a softer latex makes it well-suited for comfort,. Designed to produce softer, fluffier latex with a more consistent cell structure from top bottom. And end similarly natural, biodegradable ingredients that come from renewable resources raw! A … Talalay refers talalay latex process the pressroom where it is washed with water to remove residual and! Three times more resilient than Dunlop latex and 100 % natural makes certain this amazing feel through... Of -20 degrees modern way to process natural latex is flash-frozen as it is.! The mattress is transported to a temperature of -20 degrees material is made using an eco-friendly method! % Talalay latex, it ’ s, the mold is then flash-frozen before it 's baked firmness despite. The dimensions to ensure they meet our stringent quality standards recipe as it baked! Buoyant quality which relaxes muscles and relieves tension, lifting away the pressures the... Mix natural latex, which is used in our products with foam, transforms this renewable resource into world... Talalay delivers a unique eco-friendly production method the name Joseph Talalay, who invented Talalay... And produces a foam that is less dense, which makes it well-suited for comfort layers, but ideal. Is the difference between Dunlop latex and 100 % natural latex is cooled and removed from the mold complex! Produce the same which is used in some other latex mattresses are made in the product.