How It Works, How It's Made, Luxury Organic Latex Mattress by Mountain Air Organic Beds

STEP 1:

Latex is tapped out of botanical rubber trees called, Hevea brasiliensis rubber tree, grown certified organic. The Hevea brasiliensis botanical rubber tree can reach up to a unbelievable 141 feet tall in the wild. 
We use the “Dunlop” process, with only Sri Lankan high Quality “Organic Latex.” We also offer 100% Natural Talalay in the top layer of the Heavenly Dreams, and the Heavenly Harmony mattresses.

 

Why is organic important? 

The Truth About Toxic Mattresses.

Dunlop vs Talalay

There are two basic ways to product rubber, Dunlop and Talalay.  For the purest, it is good to know, Dunlop is the only type of latex that can be produced organically.  Talalay can not be made organic, at best Talalay can be made 100% Natural.  Buyer beware 90% of rubber produced for for mattresses is made synthetic, which is SBR, toxic to the lungs, liver, and brain.

What set's our brand apart from others?

The short answer, longevity. Other brands organic latex inconsistency is clearly visibly noticeable to the naked eye. Inconsistent processing, using old equipment almost always effects the quality of the rubber. Over a span of 2-3 years, the layers fracture inside giving the sleeper the feeling of sleeping in a dip. 


Offering the World's first certified organic latex products..... 

Our rubber is collected (just like maple syrup) into coconut cups by tapping the rubber trees.  This process is done in the early mornings in the tropics of Sri Lanka while it is still cool.  The farmer adds minute amount of ammonia or sulfur to keep the rubber from coagulating. They quickly get it to the facility nearby, to turn the sap into rubber cores we use in our mattresses. 

We are proud our supplier is a pioneer that is the first to offer certified organic latex products in the world.  We sleep better at night knowing we carry the finest products, from the oldest, most experienced, high tech producers who have invested in their own infrastructure through training, machinery, transportation...

Furthermore, we take pride ourselves in innovation, by bringing you the purist, highest quality no-compromise 100% organic latex mattresses that is fully customizable.

Value of Latex: 

Each rubber tree weeps 15 grams of latex daily. A Queen size core needs the daily output of 2,500 trees,spread over 12 acres of rubber plantation, providing a living to eight rubber tappers. Interestingly, these rubber trees accounts for the removal of 143 metric tons of Carbon DiOxide from the environment in 1 year. This is the genuine contribution to the environment by our supplier.

Once the rubber is collected, is then sent straight to their local facility, in Sri Lanka, where it is poured into molds and baked like a cake.  It evens smells a little like a cake, then it comes out of the ovens. 

Using a high-tech, computer controlled foaming machine made in the USA; air is blended with latex to achieve required density,  hardness of foam, producing the  highest quality, and purest latex rubber, Mountain Air Organic Beds require. The layers are then washed several times using drinkable quality water to ensure clean & pure product. Finally the latex uses a soft condition drying mechanism, unique to our supplier to enhance the Natural feel of the end product. 

QUALITY CONTROL

16 Points of quality control, measuring hardness, weight, & visual control.  This is where the label for density, and certification is put on the whole layers before they are cut to the size you need. All products are made at its ISO 14001-2004, 9001-2008, 50001-2011 certified production facility located in a dedicated export processing zone with excellent infrastructure facilities provided by the Board of Investment (BOI) Srilanka. 

Then it is packed flat, sealed, put in a container that is shipped directly to a US port where is sometimes inspected by customs. The container is then taken to our warehouse in California, where it is unloaded, organized, ready for picking for the next order.  
 

STEP 2:

Once we get an order, we request the custom layers from the warehouse in California.  (Our mattresses are not stored on the shelf assembled, which is not good for the rubber.) Each Mountain Air Organic Bed is made farm to bed, fresh for you. Once a order is placed, the normal delivery time is 2-3 weeks, but could take a little more time if shipments are held up in customs, inclimate weather, Holidays, or delays beyond our control.

Once the order is picked, the layers are prepared by the workers in California, by cutting and slicing, roll packing & shrink wrapping before putting in a box.  Density labels are placed on each box, so you know what density the rubber is.  FedEx Ground picks up your packages and delivers it to your home. We send you notification at that time.
  

STEP 3:

Per order, we customize the number, and types of layers to allow your mattress to personally fit each sleepers body. The layers are shipped in individual boxes and will fit into the casing, which makes assembly as simple as placing the layers into the casing and zipping it up!  Our mattresses are not one size fits all - cookie cutter type mattresses - we put the time into each mattress to make it custom for you.

STEP 4:

The frame is handmade in our woodworking shop in Arkansas. We use local exotic poplar wood, and is custom-built to fit your needs. Finished by hand rubbing several coats of hemp oil, which is safer than boiled Linseed oil, or paints, to protect the wood as it ages. 

Our beds and foundations are important because it is specifically designed for your organic mattress. Just like tires on your car, you must have proper support.

We use slats that are extra wide 5" wide for strength and spaced no more than 3" apart.  Slats are made from pine to hold up your bed for years and years. King size beds have a support beam under each sleeper for maximum, extra strong support. 

Exclusive center support legs will not permanently rack like traditional platform beds. They are designed to collapse in the event you move your bed, and you can knock them back into place with a broom handle without disassembling your bed.

Just like our mattresses, our beds and foundations are easy to take down, and reassemble if you ever move.  Everything we make is easy to get in and out of small spaces.  Great for Tiny homes, we even make custom sized beds and mattresses for RV, Trucks, Vans and Yachts.

STEP 5:

Once all of the pieces are ready to go, everything travels to its final destination where it can easily be assembled in its new home.  Each half layer up to a 3" TXL layer, weighs 22-29 pounds depending upon density.  Layers are best opened in the casing after removing the outer cover on the opposite side then flopped over to the sleeper's side you want it to be on.

We recommend you carry your layers rolled up like a sleeping bag, and flop them into position, lining up the side edges with the seams. Do not grab the rubber directly and pull, as you may tear it. Instead grab the plastic only.

Professional installation is currently $299 and available nationwide. (Haul off, is not included, we recommend you donate to a local charity.)