Latex foam

The type of latex foam most commonly found in beds and mattress products is either Talalay latex foam or Dunlop latex foam. Both of these variants have a different manufacturing process and the end products has some different characteristics.

Below is a brief summary of the two processes.

Talalay latex

Talalay gets it name from the Talalay process used to produce the latex and this process is capable of making a soft or hard foam and it ensures that the cells of the foam are consistent and round. It is a comparatively new manufacturing process.

How the Talalay latex foam is made

The unprocessed foam is poured into an aluminium mould which is sealed to create a partial vacuum. After this the temperature is reduced to minus 30 degrees centigrade.

A number of processes are then performed on the gel like latex sap to produce the spongy spring material that is found in mattresses and these processes are, Gelling, which is the addition of CO2, and Prevulcanization, which sees the foam heated to 115 degrees centigrade. This is the baking part of the process.

The next stages are washing, followed by drying and postvulcanization. These final stages see the Talalay latex take on the typical characteristics that are associated with the latex that is used in anything from mattresses and pillows to cushions and chairs.

Talalay latex foam is very consistent throughout any block and the end product’s characteristics can be controlled very effectively throughout production.

Dunlop latex

Dunlop latex has been produced since the early part of the twentieth century and it uses a simpler and less sophisticated production technique to Talalay.

The raw latex (sap) is placed in a centrifuge and frothed or whipped prior to being poured into a mould. It is then baked using steam. This process is simpler than that used to make Talalay latex.

The finished Dunlop latex has some differences to the Talalay latex, the most significant of which is that the cells are less consistent and that there is a variation in the firmness (density) between the top and the bottom of the foam. The result of this is that the Talalay latex is generally considered to be a superior material for mattress, pillow and other body supportive applications.

Most of the latex beds, pillows and top layers (on composite mattress beds) on sale today are made using the Talalay production process.