DESIGNED FOR
PRESSURE RELIEF

Latex INTL - How Latex is Made

How Latex is Made

MAKING LATEX – MANUFACTURING PROCESSES

Latex Manufacturing Processes

The terms “Talalay” and “Dunlop” refer to the two different methods of manufacturing Latex Rubber for sleep products. The Dunlop process was developed in 1929. It was the first method used to produce latex material for bedding.

As technology progressed, the Talalay process was developed by the Talalay family during World War II. The Talalay process for producing latex is significantly more complex and costly, resulting in softer, more buoyant and luxurious finished products.

MAKING LATEX - LATEX FORMULAS

Both Talalay and Dunlop processes start with a formula mixture of liquid latex. These formulas can be any of the following:

100% natural latex rubber (harvested from rubber tree plants) 
100% synthetic latex rubber (a man-made molecular copy of natural latex rubber)
Blended natural & synthetic latex rubbers (specific blend ratios are proprietary)

Note: there are small amounts of other materials required for processing liquid latex into solid form which are necessary for all latex production. (ingredients & amounts are proprietary)

Latex International Talalay is produced using only 100% Natural or Blended formulations to meet optimum quality standards.


 

Latex Processes

TALALAY

1. Liquid latex formulation is poured into a mold and sealed closed
2. Vacuum is created to disperse liquid latex throughout mold
3. Liquid latex is flash frozen 
4. Frozen latex is flash heated to “gel” into permanent solid form
5. Cooled solid latex is removed from mold

DUNLOP

1. Liquid latex formulation is poured onto a long conveyor belt
2. Liquid latex is slowly heated to “gel” into permanent solid form
3. Cooled solid latex is removed from conveyor belt



 

THE DIFFERENCE IN PROCESSING ARE THE TWO ADDITIONAL STEPS THAT OCCUR WITH TALALAY PROCESS - #2 VACUUM & #3 FREEZE .

#2 Vacuum – This allows any amount of latex to be evenly distributed throughout the mold creating precise and varied firmness with the finished latex. The more liquid latex that’s poured into the mold the firmer the resulting solid latex. Therefore, if less liquid latex is used, a softer more supple piece of latex results.

This differs from Dunlop in that Dunlop process has very little ability to vary the firmness or feel of the finished solid product while maintaining its structural integrity. The liquid formula is poured onto a belt and you get the same, dense piece of latex every time. The only way to soften the feel of Dunlop latex is to add “fillers” into the liquid latex formula which result in solid latex that is flaky and breaks down quickly.

#3 Flash Freeze – This provides Talalay with its uniquely consistent characteristic. Liquid latex is a suspension of rubber particles in water, like a shaken snow globe. Flash freezing prevents the latex particles from settling to the bottom while gelling into a solid product. This means that the resulting piece of solid Talalay latex has the same consistent feel from top to bottom.

This differs from Dunlop because Dunlop process does not utilize a freeze step. Therefore, the rubber particles settle to the bottom while the liquid latex is gelling into a solid form, like a snow globe, resulting in a variation of feel from top to bottom. This is not recognizable if the Dunlop latex is used as a bottom layer of a mattress but can cause problems if Dunlop pieces are used for pillows or as top layers of a mattress.

CONCLUSION - The Talalay process takes four times longer than Dunlop with two additional process steps that improve the consistency, quality and feel of the finished latex.

A simple analogy: Talalay latex is like a chocolate soufflé; although the process is long, your end product is a buoyant, airy, complex delight. Dunlop latex is more like a tray of brownies; tasty, but dense and flat in comparison.

 

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Latex INTL - Quality

Quality

CRAFTING EXCELLENCE

WHAT MAKES LATEX INTERNATIONAL'S TALALAY SO SPECIAL?

Our commitment to perfection: From the selection and mixing of raw materials to final product testing and assembly, our entire manufacturing facility utilizes the latest technology to create the most supple, resilient and comfortable Talalay Latex sleep products in the world.

But of course, all this technology won’t get you anywhere without smart, talented professionals to bring all the elements together assuring great finished products are delivered to your home every time.

Talalay latex is the premier material in bedding, LI Talalay delivers a unique buoyant quality which relaxes muscles and relieves tension, lifting away the pressures of the day while you sleep. Careful attention to detail at every step makes certain this amazing feel comes through in the finished product.

To help understand what makes our Talalay Latex so exceptional, think of an artisan chef creating a light and airy chocolate soufflé!

Start with the best ingredients - We utilize only the highest quality natural and synthetic latex and never introduce fillers that can degrade the feel and durability of our products. Unlike other latex manufacturers, Latex International filters the liquid latex to remove any large particles that might affect the consistency and durability of our end products. It you think of Talalay latex like a soufflé, it’s pretty clear that using powdered eggs isn’t going to suffice- you need real, farm fresh eggs!

Use the best recipe – Next, we mix our premium ingredients into a liquid latex formula or “batter”. Creating different formulas of liquid latex “batter”, we meet specific customer requests for 100% natural or more commonly used blended natural/synthetic latex recipes. Think dark chocolate vs, milk chocolate- it’s a matter of personal taste and desired product attributes.

Measure Carefully- As any great baker knows, if you don’t measure correctly the soufflé will fail. Our advanced, state of the art automated systems control both the mix of the batter and the precise amount poured into each mold to attain specific results every time.

Test for Perfection - Once the process is complete, every mattress core is robotically tested in 9 areas to assure a consistent feel from head to toe. Each pillow is individually weighed and hand inspected.

Share the Results - Even the best ingredients and the finest materials can be used poorly. To assure great finished products, we follow through by sharing knowledge with our retail and manufacturing partners. Together, we design and deliver finished pillows, mattress toppers and mattresses that bring the uplifting benefits of Talalay Latex to the surface.

Please visit our product finder page to locate products and companies in your area.

EARTH FRIENDLY

Oeko-Tex Certified

LATEX INTERNATIONAL TALALAY - ENVIRONMENTALLY CONSCIOUS

All of our Talalay products are made with Natural Talalay Latex Rubber, which starts as sap from the Havea brasiliensis tree. These rubber trees have a 25 year productive life and a strong positive effect on the environment as they quickly absorb carbon dioxide from the atmosphere and help reduce greenhouse emissions.

Our Talalay process features natural, biodegradable ingredients that come from renewable resources and water-based raw materials: natural latex, air, and water. Our process does not use solvents and does not damage the ozone layer. Our clean and green approach carries through to our end products: Talalay latex contains no toxic chemicals while standard Poly Foam and Memory Foam (visco) can contain as many as seven toxic chemicals*

OEKO-TEX CERTIFIED

The Oeko-Tex Standard 100 (link to oeko website) is the leading global testing and certification process that ensures textile materials and home furnishing products do not contain harmful substances or pose a health risk to consumers. Very few latex or foam producers in the world meet the standards of this independent, third-party certification. Click here to view our OEKO-TEX Standard Certification.

All Latex International Talalay Latex products are certified OEKO-TEX Class 100; the healthiest classification.

This means that our products do not contain allergenic materials that form carcinogenic arylamines of the MAK-groups III A1 and III A2 (see the Oeko-Tex website for a list of chemicals included in these groups,link to oeko), pesticides and chlorinated phenoles, heavy metals or formaldehyde. Our Talalay also meets the standard for skin friendly pH and is free from chloro-organic carriers and biologically active finishes.

In other words, Latex International Talalay is the healthiest material you can sleep on.

RESPONSIBLE

*Poly Foam and Visco Foam may contain up to seven toxic chemicals: Tetrachoroethane, acetone, and dimethylformamide, Methyl benzene, Methylene dianiline, toluene-neoprene and Vinilideine chloride, one non-toxic chemical - diphenyl diisocyanate, and one natural material (water.) Synthetic Latex has 5 non-toxic chemicals (2-chloro-1–3-butadiene, diphenyl diisocyanate, metallic oxides, Phenol-melamine resins, sulfur, Tellerium) and 1 natural material (water.) 100% Natural Latex has 6 non-toxic chemicals (acrylate resins, diphenyl diisocyanate, Phenol-melamine resins, Phenol-urea, Polyvinyl acetate and waxes styrene- butadiene copolymer) and 3 natural materials (fats, hevea brasiliensis milk, and water.)

PRODUCT TESTING & RESEARCH

PRESSURE MAPPING

LI Talalay Latex provides 33% more Pressure Relief than leading Memory foam.

Pressure mapping tests the amount of pressure your body registers on a selected surface. This technology is widely used throughout the bedding industry to determine the quantity of pressure that a mattress or pillow creates on your body.

Pressure from your mattress and/or pillow prevents your muscles from relaxing which makes it difficult to fall asleep and impairs circulation causing you to toss & turn which makes it difficult to stay asleep.

Therefore, the less pressure your mattress and pillow produce on your body the easier it is to fall asleep and the more complete sleep you achieve throughout the night which leads to more energetic and productive days.


 
 

DURABILITY

Latex International Talalay Latex is 4x more durable than other latex and 20x more durable than traditional bedding foams.

At Latex International, we continually ensure that our formulas will last the test of time. Using the standardized ASTM Cornell Indentation test we prove that our Talalay outlasts any other material used for bedding today.

This is the most rigorous and material damaging ASTM standardized test that exists for bedding components. While Latex International Talalay performs flawlessly over a period of 12 hours representing decades of use, other latex’s break down much more quickly and foams such as memory foam and polyurethane foam actually tear apart within minutes.

The strength of our material allows LI to match any warranty that retail stores choose to offer on their products and assures maximum value for consumers.

BREATHABILITY

Latex International Talalay Latex breathes up to 7x better than other latex or foams for cooler sleep.

One of the fastest growing concerns with bedding today is sleeping hot. This is a legitimate concern because not only is it uncomfortable, sleeping too hot interrupts the quality of our sleep as we continuously move to find a cooler spot. This can occur from both mattresses and pillows.

The heightened awareness of sleeping hot is primarily due to increased use of Memory Foam in mattresses. Memory Foam has a collapsible cell structure that traps body heat and radiates it back at us resulting in uncomfortable perspiration.

Talalay Latex is sometimes confused with Memory Foam because of extensive Memory Foam advertising. Nothing could be farther from the truth. The Talalay Latex rubber cell structure resists collapsing and allows air to circulate. This breathability whisks away our body heat preventing mattresses and pillows from becoming an oven.

Latex International has gone one step further and developed Talalay GL which is a unique formulation of Talalay Latex with special phase change properties. Talalay GL actually helps regulate the consistency of body temperature for a temperature neutral sleeping experience.

Bedding Allergens BEDDING ALLERGENS
Mold, Mildew, Bacteria & Dust Mites

LI Talalay Latex is Mold, Mildew & Bacteria proof and Dust Mite resistant

Most people don’t consider their mattress as a contributing source for respiratory problems and allergic reactions. We think of our bed as a “safe haven”. The reality can be much more yucky.

Mold, mildew, bacteria and dust mites love our beds & pillows. We shed millions of microscopic skin cells and perspire nearly 1 pint of water every night. The microscopic skin cells and water vapor fall through the weave of our linens and mattress cover landing on the cushioning layers below where they become a food and water source for mold, mildew, bacteria and dust mites- it can’t be avoided, and it's gross.

Whether your “landing pad” cushion layer is hospitable to these infestations is the controlling factor to the amount of hazardous dust created from your mattress & pillow.

Foams such as Memory Foam & Polyurethane Foam are environments where these contaminants thrive, so if they compose the top cushion layers of your mattress you may have a problem.

Independent testing shows that Latex International Talalay Latex is mold, mildew & bacteria proof- these organisms simply won’t grow on it. Furthermore, it’s dust mite resistant so these critters will prefer to be elsewhere, not right next to your face as you sleep.

TOXIN FREE

Try to find a healthier bedding material, we dare you.

In a perfect world all bedding products would be as safe as Latex International's Talalay Latex. The reality is that today’s technology for producing foams like Memory Foam or Polyurethane Foam simply aren't.

Today’s foams may contain any or all of the following, each are known carcinogens.

Latex International Talalay Latex contains none of these.

LATEX ALLERGENS

Zero cases of allergic reactions to LI products have been reported.

Latex International has been making Talalay pillows and mattress components for over 35 years. Every year millions of products are sold using Latex International Talalay.

The FDA tracks allergic reactions to latex products in the USA. Not once has there been a report of an allergic reaction attributed to any of our Talalay products.

CONSISTENCY TESTING- MATTRESSES & PILLOW

Latex International is the only latex producer that tests every block of mattress material in 9 separate areas to insure consistency throughout each piece. This means that retailers and consumers can be sure that products delivered or brought home will match the products experienced in the showroom every single time.


  
 

Because pillows are not able to be measured in the same way as block mattress material, we electronically weigh and then hand inspect every pillow for quality and consistency. This is an extra time consuming step in our process, but it’s the only way to be completely sure that consumers receive the very highest quality pillows every single time.

WHO MAKES THE MOST PRESSURE RELIEVING MATTRESS?

XSENSOR Las Vegas Market Industry Furniture Show January 30, 2013

"Extroardinary Pressure Relieving Mattress!"

 

DESIGNED FOR
PRESSURE RELIEF


No Yellows, Greens or Reds - All Blue!!


Organic-Cotton 11 - "Extroardinary Pressure Relieving Mattress!"
 


XSENSOR Measuring Pressure Mapping System on the Latex-pedic® Organic-Cotton Mattress

See Live Pressure Imaging Sample
http://www.xsensor.com/swf/xsensor-bed.html

Integrating XSENSOR’s powerful pressure imaging

tools into the mattress buying process can provide

many benefits to customers:

Help them understand peak pressure points and mattress

support

Show how your mattresses can be pressure relieving and

provide good mattress support

Help justify the cost of a higher priced mattress to

improve sleep

latex mattresses
Natural, Organic and 100% Pure Talalay Latex Mattresses

If you are in the market for a Natural, Organic Latex Mattress, please call Latex-Pedic or visit one of our Factory Showrooms in Burbank, Garden Grove and Phoenix AZ.  All our Latex Mattresses can be made using Natural, Organic Latex from Latex International. 
Model LM- 7" Latex Mattress - using a 6" Natural Organic Latex Core
Model HP - 9" High Profile Latex Mattress - using a 6" Natural Organic Latex Core with 1" of Softer Latex on both sides
Model PC - 9" Pocketed Coil Latex Mattress - using 3.5" Pocketed Coil Core with 2" of Latex on Both Sides
Model OC - 11" Organic Cotton Latex Mattress - using a 6" Natural Organic Latex Core with 1.5" of Softer Latex (24ILD) on both sides

We ONLY charge you $300. more to make you a Natural Organic Mattress.  If you wish the Core to be Certified Organic, we charge you an additional $300.00 (but we recommend to get the Natural-Organic Core from Latex International and save the additional $300.00 charge)..

907 Hollywood Way, Burbank CA
800-233-7382
12557 Harbor Blvd., Garden Grove CA
800-824-3145

SERVING ALL LOS ANGELES AND SOUTHERN CALIFORNIA:  Alhambra, Anaheim, Buena-Park, Burbank, Carlsbad, Corona, Carson, Chula Vista  Compton, El Cajon, El Monte, Escondido, Fontana, Fullerton, Garden Grove, Glendale, Hawthorne Hemet, Hesperia Huntington Beach, Indio, Irvine, Lakewood, Lancaster, Long Beach, Los Angeles, Mission Viejo, Moreno Valley, Murrieta, Newport Beach, Norwalk, Oceanside, Ontario, Orange Oxnard, Palmdale, Pasadena, Pomona, Rancho Cucamonga, Riverside, San Bernardino, San Diego, Santa Ana, Santa Clarita, Santa Monica, Simi Valley, Southgate, Temecula, Thousand Oaks, Torrance, Victorville, Vista, West Covina, Westminster, Whittier

1035 E. Camelback Rd. Phoenix AZ 85014 602-277-0706 800-733-1818
SERVING: Tucson, Mesa, Chandler, Glendale AZ, Scottsdale, Gilbert, Tempe, Peoria, Surprise, and all metro

latex mattressesAuthorized Dealer.
Natural, Organic & 100% Pure Talalay Latex-Pedic® Mattresses

Natural Mattresses

Organic Mattresses

100% Pure Talalay Latex Mattresses

907 Hollywood Way, Burbank CA 800-354-5040
 12557 Harbor Blvd., Garden Grove CA 800-824-3145
1035 E. Camelback Rd. Phoenix AZ  602-277-0706   800-733-1818
 

 

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