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What is Talalay Latex?
Talalay latex gets its name from the Talalay brothers who in the 1950s perfected a new method for manufacturing latex. The process was based on first expanding the latex foam to fill a mould, freezing it to capture the bubbles and then gelling it with carbon dioxide gas. The result is a product with lower density, coupled with greater uniformity and consistency that can be washed. The process results in a versatile product, which allows a range of comfort and support options.
The Talalay Production Process
Dunlop Latex Foam Ltd. takes natural latex and blends it with a synthetic latex (SBR). This blended mixture is then ready to be turned into latex foam, using the Talalay production process.
 
A measured amount of slightly foamed latex is poured into a large fixed mould to only partially fill it. The lid is then sealed and the latex is expanded by vacuum to completely fill the mould. As soon as the latex has filled the mould it is ‘held’ and prevented from collapsing by rapidly dropping the temperature to -30°C and freezing it solid.
 
At this point, carbon dioxide gas is passed through the latex and the temperature raised to 115°C, which sets and vulcanises it, after which the lid of the mould automatically opens, and the product is stripped and placed on a conveyor.
 
The latex block or pillow is transferred first through a washer to rinse out any residual detergents and impurities before passing through a mangle to squeeze out the water.
 
The product then travels through a system of overhead dryers prior to reaching a physical testing station. Every latex block and pillow is individually tested to ensure it meets the required specifications for density and hardness, prior to despatch or conversion into a mattress.
 
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