If your would like to substitute talalay for any of your layers, please indicate that in the notes section of your cart!
The Dunlop and Talalay Processes are the Two Main Techniques Used to Develop Latex
Each rubber tree weeps 15 grams of latex per day. A Queen size core needs the daily output of 2,500 trees, spread over 12 acres of rubber plantation, providing a living for eight rubber tappers. Interestingly, these rubber trees are responsible for the removal of 143 metric tons of carbon dioxide from the environment in one year. This is the genuine contribution to the environment of the organic process. The sap is harvested, whipped into a froth, then baked into sheets in huge steam molds. Both the Dunlop and Talalay process rely on this method of generating the foam, called "vulcanization." A steam cure technique with design engineered stainless steel pin molds for energy efficiency. This technique keeps the natural latex characteristics undisturbed through the vulcanizing process. Once the foam layers are created, they get a good bathing in a multi-cycle washing method using drinkable quality water to ensure clean and pure layers.
How the Dunlop Process Works:
The Dunlop latex foam has been made the in the same fashion since the 1920s, although processing methods have advanced. Dunlop is the densest herbal latex, and is available in a variety of firmness levels.
The Dunlop production process is the most energy-efficient method of producing latex foam. While the latex is still in liquid form, it is foamed and poured into a mold. The mold is then closed up and placed on a conveyor belt. The mold is then moved on the conveyor belt into a vulcanization oven.
After vulcanization is complete, the latex foam can be removed from the mold and placed into a washing station. The foam is thoroughly washed to remove any soaps and excess materials from the foam. Thorough washing of the foam allows the foam retain its elasticity, counters aging and ensures its purity. After washing, the foam is dried at a high temperature to remove all moisture from the final product.
How the Talalay Process Works:
The Talalay process is a more energy-intensive process of producing latex foam. Many steps of the Talalay process are actually quite similar to the Dunlop process.
As with Dunlop process foam, the latex is foamed and poured into a large mold. In the Talalay process, however, the mold is only partially filled. The lid of the mold is sealed and the latex is expanded by vacuum to fill the mold. Once fully expanded, the mold is frozen. At this point, carbon dioxide gas is pushed through the latex, which causes it to gel. One compound called styrene butadiene rubber (a form of synthetic latex used by some latex mattress stores) is mixed with the latex from the trees to form the final Talalay product. Some rare companies overseas still produces a Talalay product that is free of styrene butadyne, but have come to find out that the layers give away after a couple years of sleeping. The temperature is then raised to 220ºF to vulcanize the latex. As with the Dunlop process, Talalay process foam is thoroughly washed and eventually dried after it is vulcanized.
The Main Differences Between Dunlop and Talalay Foam:
Dunlop foam is springy, Talalay foam is bouncy.
Dunlop foam is denser than Talalay foam.
The production process of Dunlop foam is more simple and energy efficient.
Talalay is a mixture of chemical and latex, whereas Dunlop is all latex.
Not all Talalay and Dunlop foam feels the same. There are many variations that can be made of each type of froth. Both Dunlop and Talalay foam can be made with or without synthetic latex. Both types of foam can be made with or without added fillers. Changes in the sort of latex or filler percentages can have major impacts on the performance of the latex foam.
Our Certified Organic Latex
Our organic-foam latex cores, toppers and pillows are made using certified organic latex that is free from chemical fertilizers, growth regulators, livestock fed additives and 600 varieties of commonly used pesticides in agriculture. It is ttoxic free, carbon neutralized, and meets the human-ecological requirements of the standard presently established for baby articles by Oeko-Tex standard 100-Class 01 certification.
The raw material, organic latex, is harvested from rubber plantations that are certified according to USDA-NOP (United States Department of Agriculture), EU (European Union) standards.
Our mattresses are manufactured and certified according to "Global Organic Latex Standard" (GOLS) of the Control Union of Netherlands (CU).
Some latex is certified organic. If you are shopping for a 100% organic mattress, you need to think about more than latex. Some manufacturers will market their beds as completely organic when in reality only one or two components are certified organic. The cover, fire barrier, mattress core and every other part of the bed should have a certification showing it is organic.