Talalay Process

Step 1: Compounding

Combination of liquid latex, soaps and rubber curing agents are mixed together in a temperature controlled, stainless steel tank to create a batter.

step 1: compounding image of tanks
Step 2: Molding

The batter is transferred to the pressroom where it is whipped into a froth and injected into an aluminum pincore mold. The pins create the unique aerated cell structure of our latex.

The mold is sealed and a vacuum is pulled to extract air and completely fill the mold cavity with foam.

step 2: molding image of filling cooling
Step 3: Flash Freeze

The batter is frozen to a temperature of -20 degrees. Freezing is unique to the Talalay process to prevent particles from settling, ensuring a consistent cell structure.

step 3: flash freeze image showing closed press
Step 4: Heated to Gel into Solid Form

CO2 is added to whip the recipe into a frothy state. Temperatures exceeding 220F-degree are applied to cure the recipe as it is baked into a solid state.

steam-core
Step 5: Cooling

The solid latex is cooled and removed from the mold.

step 5: cooling image of core on mold
Step 6: Fresh water rinse for purity

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 multi-stage fresh water rinse is also unique to the Talalay process.

Talalay process washes out more proteins than Dunlop
Step 7: Curing Process

The mattress is transported to a two-lane dryer, which completes the curing process and removes residual moisture.

step 7: curing process image of mattress dryer
Step 8: Quality Testing – Only the best pass the test!

Once dry, EVERY mattress undergoes a nine-point firmness consistency test and infrared technology scan to ensure they meet our stringent quality standards.

test_wscreen
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