FIVE BASIC TYPES OF LATEX USED IN MATTRESSES
Dunlop Mfg Process- using only natural liquid latex
Dunlop Mfg Process- using a blend of natural liquid latex and synthetic liquid latex
Dunlop Mfg Process- using only synthetic liquid latex
Talalay Mfg Process- using only natural liquid latex
Talalay Mfg Process- using a blend of natural liquid latex and synthetic liquid latex
MINOR BLEMISHES, INCONSISTENCIES, AND VOIDS IN NATURAL LATEX
When looking at raw latex it is common to see minor blemishes, slight discoloration, and small air bubbles which are commonly referred to as “voids” in manufacturing language. These are part of the product and in no way deter from the comfort performance and longevity of the latex contained in the mattress. In most cases the latex in your latex mattress is natural and will be whipped with air, much like whipping cake batter.
DISCOLORATION: In order to turn this “latex batter” into a latex mattress core, external heat needs to be applied. (This differs from the manufacture of common polyurethane foam which gets its needed heat from internal chemicals which cause a chain reaction to expand polyurethane foam.) In the manufacturer of latex mattress cores external heat is transmitted thru the aluminum sealed container and thru the aluminum rods positioned on the top and bottom of the mold. In some cases the heat can vary causing slight color changes.
VOIDS: Latex liquid is whipped with air and then poured into molds, as heat is applied any small air pockets will be expanded and become more visible when you slice the core into individual layers. These voids are usually undetected if the core is left intact without slicing. Voids are more prevelent in a 100% all natural latex mattress core produced by the “dunlop process,” and it is common to see small latex plugs to fill the voids. The voids are filled with the same latex that makes up the core and is done by hand as the latex core moves thru the manufacturing line.
BLEMISHES / GLUE SEAMS: Blemishes are a variation of voids and arise when removing finished latex cores form their molds. In some cases there can be slight tears or spots of rough surface contrasting with the smooth consistent surface on top and bottom. These minor imperfections are repaired with non toxic water-based glue. Latex cores are generally produced in cores measuring 40″ x 80″ and will need to be cut and glued to arrive at the different size mattresses: queen 60 x 80, king 76 x 80, and Cal. king 72 x 84. These glue seams are part of the finished product and do not interfere with sleeping comfort.
SLEEP EZ LATEX MATTRESSES ARE DESIGNED FOR ADJUSTMENT AND ARE OPEN FOR INSPECTION
Our latex mattresses are designed in approx 3″ layers of latex of different firmness contained in a removable zipper cover. Conventional mattresses, as well as latex mattresses made by Sealy, Serta, Simmons, and Spring Air are contained in closed, non-removable covers which prevent you from looking at the actual components inside the mattress. In addition, you can’t make adjustments without exchanging your mattress.
PICTURES OF NATURAL AND BLENDED RAW LATEX USING BOTH DUNLOP AND TALALAY PROCESS SHOWS THAT LATEX IS NOT ALWAYS PICTURE PERFECT
Talalay process b
lended latex is the most perfect product in terms of visual perfection, consistency of firmnesses, range of firmnesses (from ultra soft to super firm), and durability. For the past 40 years it has been deemed the best and we as mattress manufacturers have paid a premium to put it into a mattress.
But times have changed and with more demand for an all natural product the Talalay process was applied to 100% natural latex without synthetic blended into the mixture. There are three problems with 100% natural latex manufactured using the talalay process: (1) extra firm not available above 39-40 ild due to the conflict between the natural substance and the freezing step in the talalay process. (2) 100% natural talalay under 22 ild will lack the durability of talalay blended. (3) 100% natural talalay does not have the cell strength as blended.
TALALAY 100% NATURAL WHEN SLICED INTO LAYERS
The picture on left is of latex mattress core from the inside when sliced into two layers. This component is perfect in every way as far as its intended use inside a mattress, for support and comfort.
What it lacks is visual perfection. We can see the minor voids, and a slight brownish discoloration on one area.
This photo is raw natural latex manufacturered using the dunlop process. The dunlop process is used universally throughout the world for producing “100% all natural” liquid latex. Example is what to expect in the way it looks. Notice areas that are not smooth. This is a perfectly good latex core used in mattresses made by Sealy, Simmons, Serta, as well as any mattress manufacturer producing enclosed latex mattresses.
Some companies may ask latex core manufacturers to grade finished cores, and purchase only the cores that meet a certain standard from a cosmetic standpoint. Naturally they will have to pay a higher price for the product and pass it along to the consumer.
Photo to left is another raw all natural latex core manufactured using the dunlop process. This core was produced in queen size mold, thereby eliminating any fabrication or glue seam. Some latex core manufacturers have cores in the various finished mattress sizes, but the most common size is twin XL. Glue seams are to be considered a part of the manufacturing process and in no way make the latex core better because it does not have a glue seam.
Two twin XL latex cores side by side showing slight discolorations and minor voids. In some cases a latex core will come thrugh production with larger than accepatable voids, or large bubble holes. At this point in the production the core will be pulled aside and manually repaired by adding the same firmness of liquid latex to fill the void.
In conclusion the following facts apply to latex mattress cores:
- Natural latex cores still retain the same high qualities even though they may not be as cosmetically attractive to the eye.
- The talalay process produces latex cores with the fewest voids and blemishes in the blended and all natural, but the blended is superior in comfort and durability.
- 100% natural latex produced using the talalay process is not as good a value to the consumer as talalay blended.
- Dunlop process has been improved through technical advances over the past few years to the point of marginal difference.
I hope this article has been informative and welcome your comments.,