Combination of liquid latex, soaps and rubber curing agents are mixed together in a temperature controlled, stainless steel tank to create a batter.
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.
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.
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.
The solid latex is cooled and removed from the mold.
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.
The mattress is transported to a two-lane dryer, which completes the curing process and removes residual moisture.
Once dry, EVERY mattress undergoes a nine-point firmness consistency test and infrared technology scan to ensure they meet our stringent quality standards.