Production processes

In the early twentieth century (1910), the company Dunlop started manufacturing latex core for rest through their own process of transformation of the initial latex emulsion.


This process was the precursor or the basis for all subsequent processes for latex foam. 


Basically, the most important difference between processes, is the type of gelling or coagulating agent (for passing the aqueous solution into solid) used: Dunlop process uses FSS. In contrast, the Talalay process, the gelling agent is CO2 (carbon dioxide).

Manufacturing synthetic and natural cores

This is the latex manufacturing process more used in the world.

First, we must do the mixing of all components into compound  (a) to send it to a continuous foamer (c) unsing compressed air (necessary to make a foam) (b). At the same time, the mold is cleaned (d) and heated (e) for subsequent filling. 
We fill the mold with latex foam (1) until it fills the mold completely and placed in the oven vulcanization (3). Vulcanization is the process of latex hardening per share on the temperature and the presence of sulfur. 
Once the mattress is ready, we proceed to its demould (4), washing (5) and drying (6). 
A new core for a latex mattress or  pillow is now ready for control and storage. 


Manufacturing Talalay latex cores

In 1956, Joseph Anton Talalay invents the Talalay latex manufacturing process, starting from the same raw materials but using variations in the transformation process.


First, as in the Dunlop process, the mix of components is created. Once the mix is done, is introduced into the mould by aspiration.


Through this aspiration process the compound is homogenized mold, ie the molecules are distributed uniformly and increase its size.


Subsequently, the mixture is subjected to a freezing process at -28 ° C. Through this process succeeds in breaking the cells outer membrane to get an open cell structure that provides many benefits to Talalay latex and, consequently, to our rest.


The next step is the injection of the gelling agent, CO2 in the case of the Talalay process. The addition of this agent is to stabilize the structure of latex. 


Then proceed to the vulcanization (115 ° C), as in the traditional process. THe next steps are 1) remove the mold material through cooling to 30 ° C, 2) washing and 3) drying. 


The Talalay process offers an extremely fine latex, with excellent properties for rest and a high capacity for ventilation (breathing open cell). 


Related articles:

• What is latex?.
• Latex in our rest.