Dunlop Latex vs. Talalay Latex – The Process of Manufacturing a Latex Mattress

Dunlop Latex vs. Talalay Latex – The Process of Manufacturing a Latex Mattress

Latex mattresses are a uniquely manufactured genre of mattresses. They are more long-lasting and offer a variety of comfort levels for the users. This customized experience makes them a bestseller in the market. This article will describe how a latex mattress usually comes about and what are the different production processes: Dunlop method and Talalay method.

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The first cycle: obtaining latex

These mattresses are made up of Latex, which is an organic sap obtained from the rubber tree. It is milky-white in color and rubbery in texture – a completely different composition of the same material before it is converted into a mattress.

Most rubber tree plantations are located in Southeast Asia. Each rubber tree has a lifespan of 100 years, and each new sapling takes about 6 years to grow into a fully formed tree that can produce latex. All it takes is a thin cut on the tree to remove a piece of bark, and the sap lows out into buckets.

 

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The second cycle: rationing the latex

A large amount of latex is needed to make an average sized latex mattress. For a single queen sized bed, about 12 acres worth of rubber trees need to seep out latex for a day. However, know that the organic nature of a latex mattress is completely environmentally and economically sound. Not only does the purchase of a latex mattress encourage the growth of more rubber tree plantations, these trees suck out the pollution from the environment. Aside from that, the work at a rubber plantation creates job opportunities in area where stable jobs might be hard to find.

The third cycle: liquid latex into mattress

Turning liquid latex into mattress is called processing. It includes mixing the latex with a series of materials that help it solidify and there are several ways to do that. Two common methods are the Dunlop Method and the Talalay method. The differences between the two are the following:

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  1. Dunlop Method

The Dunlop method works in the following way:

  • The liquid latex is mixed until it foams.
  • This foam is then placed into a mould to be shaped a certain way.
  • It is passed into the oven which solidifies this mould.
  • Then this solid mould is placed into a washing belt to wash away any excess latex and unreacting agents.
  • This method lets us create any shape of mattress in a single go.
  1. Talalay Method

The Talalay method works in the following way:

  • It is a relatively newer process and its mattress textures are different from that of the Dunlop method.
  • In this method, the liquid latex is shaped into a certain mould and then sealed closed.
  • A vacuum application evenly distributes the latex in the mould.
  • After that it is flash frozen and then abruptly flash heated so that the mixture solidifies.
  • After that, the solid block is removed and is ready for use.

Note that the latex mattress made by the Talalay method cannot be made in one fell swoop like the Dunlop method. Instead it is made from smaller blocks that are glued together.

We hope the above information gives you a better understanding of the process of manufacturing a Latex Mattress.

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