Superior Quality -- The Talalay Process

Compounding

Natural latex is extracted from the tropical rubber tree in a way that is similar to tapping a maple tree for syrup. Natural and man-made latexes, soaps and rubber curing agents are precisely mixed in a temperature-controlled, stainless steel tank. Quality checks are performed on Ph, viscosity and temperature.

Molding

The compound mix is transferred to the pressroom where it is whipped into a frothy liquid form with the consistency of vanilla soft serve ice cream; a robotic arm then injects the foamed liquid latex into an aluminum pin core mold. The pins create our unique aerated cell structure. The robotic systems distribute the mixture evenly to ensure consistency and final product density. The mold is sealed and a vacuum is pulled to extract air and completely fill the mold cavity with latex. The latex is chilled at -20 ° Fahrenheit. Freezing (unique to the Talalay process) prevents particles from settling and ensures a consistent cell structure. CO2 is introduced to gel the latex. The mold is heated to 220º Fahrenheit to cure the core as it is baked into its final state.

Washing

Unlike other latex manufacturers, Latex International washes EVERY mattress core and pillow. The latex core is removed from the mold and placed on a conveyer belt that carries it through a five-stage fresh water rinsing—the only one of its kind in the industry. Five banks of 12 self-cleaning water jets wash away residual soaps, curing agents and proteins. Between each set of jets, the products are squeezed to less than 4% of their total thickness to remove the maximum amount of residual materials from deep within the product. This vital step improves durability and comfort by removing residual soaps, curing agents, and proteins that could cause premature softening of the product.

Drying

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

Quality Testing & Fabrication

Once dry, every mattress core undergoes a rigorous nine-point pressure/firmness/consistency test to ensure all cores meet stringent quality standards with even density across the core. Cores are expertly cut and constructed to meet our customers’ product specifications. Our fabrication facilities are able to create custom contours, support zones, edge support and even inlay alternate materials such as visco-elastic foam. Environmentally sound, water-soluble glue is used to create an exceptionally secure bond that maintains high product performance. To watch a video of this complete process go to Talalay Latex Video

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