Measure the latex sponge layers of thickness and density. In fact, it’s three times more resilient than Dunlop Latex, which is used in some other latex mattresses. Talalay describes the manufacturing process of creating a latex mattress out of latex foam rubber. They apply a vacuum. The natural latex sap covered and steam baked. Talalay Latex is the premier material in bedding. Careful attention to detail at every step makes certain this amazing feel comes through in the finished product. How Latex Foam is Made: Both Dunlop and Latex processes begin and end similarly. Substances are add to stabilize the sap. Molding. The Talalay process features natural, biodegradable ingredients that come from renewable resources and raw materials: natural latex, air and water. The Talalay process features … Talalay Manufacturing Process The two steps necessary to develop Talalay, that are missing from the standard process, are the … The QC team will inspect all items for visual and physical defects, weigh and measure the dimensions to ensure products meet exact specifications. Go behind the scene and watch how our Talalay latex mattresses are made in Shelton, CT. Add air to the mixture to foam the latex compound. The milky white rubber sap is whipped into a froth consistency using a centrifuge. This does not mean that it is softer. We’re getting to the difference between Talalay and Dunlop soon, I promise. The latex mixture is filled with air and injected in a mould. The Talalay process follows these steps: 1. However, during the Talalay process, it’s only partially heated up, rather than fully solidified. Latex foam is … The mixture is agitated to foam and poured into a mold with aluminum cores. This process enables the round, opekeeps to keep their shape. The Talalay process is a more energy intensive process of producing latex foam. Our Talalay delivers a unique buoyant quality which relaxes muscles and relieves tension, lifting away the pressures of the day while you sleep. Talalay latex rubber is made using an eco-friendly production method. Similar process has been used since 1929 . 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. We have never received any feedback from consumers with regards to latex allergy linked to the proteins that cause the allergy. The latex is than expanded through a vacuum before being flash frozen at -30°C (-(22°F). A Talalaly latex topper is an easy and economical solution to revitalize your bed. The reason is that the proteins are washed out during the production process and the latex is tucked in the mattress. The batter is frozen to a temperature of -20 degrees. 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. The manufacturing process for organic latex and 100% natural latex is the same. In the Talalay process, however, the mold is only partially filled. Dunlop latex and Talalay latex are not two different kinds of latex. Combination of liquid latex, soaps and rubber curing agents are mixed together in a temperature controlled, stainless steel tank to create a batter. 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. The Talalay process is designed to produce softer, fluffier latex with a more homogenous consistency. In Talalay latex production, the latex is subjected to vacuum molding and flash freezing. Cut or assemble the layers to produce latex cores of different widths. Our Talalay delivers a unique buoyant quality which relaxes muscles and relieves tension, lifting away the pressures of the day while you sleep. Whipped latex partially fills a mold. The Talalay process adds two steps. Talalay refers to the name Joseph Talalay, who invented the Talalay production process. Vacuum the sealed mold so that the foam fills up the inner space of the mold. The mold is then flash-frozen before it's baked. Developed in the 50’s, the talalay latex manufacturing process uses less liquid latex to produce the same depth of core. 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. Talalay vs Dunlop Talalay and Dunlop are two types of natural latex but they are different in terms of feel and the overall manufacturing process. Mix natural latex, soap booster, anti-aging agent and zinc oxide according product formulas. For somebody with latex allergy, Vita Talalay is safe. The quality of the end product is identical. The result is a more even feel and more flexible mattress that gives you the support and softness you need. The batter is transferred to the pressroom where it is whipped into a froth and injected into … Talalay toppers are made of 100% Talalay latex, which gives you the same luxurious feel. The latex mattress core is removed from the mold and placed on a conveyer belt that brings it through a five-stage fresh water washer, which removes latex proteins, residual soaps and curing agents. The aluminum needles can create a unique aeration structurethat naturally increases gas … Instead of fully heating the latex, it’s immediately flash-frozen. Of the total talalay latex process for both companies approximately 95% is blended and 5% natural. The mold is sealed and a vacuum is pulled to extract air and completely fill the mold cavity with foam. This process describes the production of Talalay latex which is used in our products. Talalay is more responsive and best for those who sleep on their side while Dunlop is the denser of the two types of latex and offers incredible support. The batter is transferred to the pressroom where it is whipped into a froth and injected into an aluminum pincore mold. Process begins with the sap that’s collected from the rubber tree. The resulting foam is softer and much less dense, which makes it well-suited for comfort layers, but not ideal for support cores. is the premier material in bedding. This raw material is made into Talalay latex foam through a complex freeze-vacuum process. The Talalay Process. Natural rubber is harvested from the sap of the rubber tree (Hevea Brasiliensis)- originated in Brazil- and now mainly grown in Malaysia, Thailand and Indonesia. Once dry, EVERY mattress undergoes a nine-point firmness consistency test and infrared technology scan to ensure they meet our stringent quality standards. Both processes produce latex with the same options in firmness, despite some claims that Talalay makes a softer latex. The mixture is agitated to foam and poured into a mold with aluminum cores. Dunlopillo was really the only source of "natural talalay" latex until 2005 when Latex International and an "all natural formula" to the "Talatech"™ line. The Talalay process, a unique eco-friendly production method, transforms this renewable resource into the world’s finest latex foam. Talalay Latex'sunique freezing course at -30°C prevents the deposition of particles and ensures a consistent cell structure, thus ensuring consistent qualityand touch. Talalay latex has a more consistent cell structure from top to bottom and edge to edge. 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. Squeeze water out of the latex sponge by squeeze rollers and evaporates all the water with drying machine. Talalay Step-By-Step Process. a. 100% Natural Dunlop or Talalay Latex: Like organic latex, 100% natural is made from the sap of the rubber tree which is processed (see manufacturing process for Dunlop and Talalay). The sap is then poured into a mold. Instead, they refer to two different processes used to make latex. Mix latex compound according product formulas in temperature controlled tanks. 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. 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. Talalay foam can be produced in a variety of firmness levels. The next step … Careful attention to detail at every step makes certain this amazing feel comes through in the finished product. Talalay Latex rubber is extremely durable. Fill in carbon dioxide to gel the foam, and it is finally vulcanized at 110°C to make the foam solid into a uniform bubble distribution. Differences Between Dunlop and Talalay Latex in Mattresses The solid latex is cooled and removed from the mold. After the latex sponge is removed from the mold, it is washed with water to remove residual soap and curing agent. The Talalay latex process started after the World War II, and it requires more work and capital when compared to the Dunlop latex process. Fill in carbon dioxide to gel the foam, and it is finally vulcanized at 110°C to make the foam solid into a uniform bubble distribution. The pins create the unique aerated cell structure of our latex. 2004 International Pkwy, Fredericksburg, VA 22406. Freezing is unique to the Talalay process to prevent particles from settling, ensuring a consistent cell structure. The first step includes whipping the liquid latex extract into a froth. CO2 is added to whip the recipe into a frothy state. The manufacturing process for Talalay Latex is more complex and adds two extra steps to the process, making the feel of the mattress more consistent. Dunlop vs Talalay Latex What is the difference between Dunlop Latex and Talalaly Latex mattress layers? 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 liquid latex is emulsified in a … The multi-stage fresh water rinse is also unique to the Talalay process. Then the vulcanization process is performed in a steam heated environment. Dunlop and Talalay refer to the process by which liquid latex is transformed into sheets of latex foam. 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). Talalay Latex Manifacturing Process. The liquid latex extract is whipped … It is similar to the Dunlop process, but with a few additional steps (you can see the full FloBeds Talalay process here). The mattress is transported to a two-lane dryer, which completes the curing process and removes residual moisture. Latex foam is made from a conc How Latex Foam is Made: Both Dunlop and Latex processes begin and end similarly. Both processes can be used to make natural or synthetic latex or blended latex. save 15% OFF than Amazon. Dunlop and Talalay refer to the process by which liquid latex is transformed into sheets of latex foam. Natural Talalay Latex Foam. TALALAY LATEX MANUFACTURING PROCESS Mix natural latex, soap booster, anti-aging agent and zinc oxide according product formulas. After the latex is poured, the mold is sealed and the process is continued in a vacuum chamber. 120 Day Free Return & Ship | Order Now! Here they use vacuum sealed metal molds. The Talalay manufacturing process is a more modern way to process natural latex and produces a foam that is less dense than Dunlop foam. If you don’t have a Talalay latex mattress yet, you can still experience the luxurious feel and uplifting qualities of Talalay … As with Dunlop process foam, the latex is foamed and poured into a large mold. 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