Talalay Latex
A common misconception is that Talalay refers to a type of rubber plant or brand moniker. The name actually refers to the process that latex goes through when being formed into a single piece of rubber foam. Developed in the 1940’s by the BF Goodrich Company, Talalay (ta-la-lay) foam is created by pouring a latex mixture into a mold that is subsequently vacuumed of air, and then flash frozen to stabilize the cell structure of the mixture. The frozen material is then combined with carbon dioxide and baked until it solidifies into the final product.
the talalay advantage
The result is a mattress that contains a more consistent distribution of air bubbles, which is what gives it its pliability and pillowy-soft surface feel. As latex material is naturally strong and resilient, it is also very supportive and can withstand quite a bit of weight and pressure – so sleepers will get a perfect blend of softness and support. The open cell structure of Talalay latex also ends up being 400% more breathable than its competitors, including memory foam as well as Dunlop processed latex foam.
The biggest advantage of natural Talalay latex is that it requires no volatile petroleum based chemicals in order to be created. This means that it will not give off any undesirable synthetic toxins or fumes and the innate attributes of latex that is sourced botanically will not be muted – mattresses are incredibly durable, are mold, mildew, bacteria and dust mite resistant, are hypoallergenic as well as completely biodegradable. They are also a completely sustainable solution as natural latex is a renewable resource.
The Production Process
Step 1 - Mix
The process begins when twice-filtered natural latex is combined with natural soaps and curing agents in a temperature controlled, stainless steel mixing tank. Our Siemens controlled system monitors the temperature, consistency, and viscosity of the compound inside the tanks to maintain ideal conditions.
Step 2 - Pour
The finished compound is the transferred to foamers in the computer-controlled pressroom that features size cells of pin core molds. The latex compound is the whipped into a frothy liquid and precisely poured into molds that look like waffle irons. The pincore molds help create the unique aerated cell structure of the Talalay latex.
Step 3 - Vacuum & Freeze
The Talalay process features two unique steps: vacuum and freeze - that produce the superior consistency and feel of our Talalay products. After the pour is complete, the mold is closed and sealed. Air is extracted and a vacuum is formed, perfectly distributing the liquid latex within the mold. The vacuum stage allows for even and consistent distribution of latex compound in the mold which allows for different and distinct feels/firmness to be produced.
The compound is then chilled to minus 20 degrees Fahrenheit, freezing the latex particles into place before gravity causes them to settle. This critical step is what assures firmness consistency in the final product by keeping the evenly dispersed compound within the mold to remain in place and not settle while the latex foam hardens or cures.
Step 4 - Heat
The compound is then heated to 220 degrees to cure the latex into its final shape. Once the curing cycle is complete, the mold opens automatically and the product is transferred to a conveyor system, which sorts the products for washing and drying.
Step 5 - Wash
The first stop is a five-stage fresh water washer to provide a pure product. The products are squeezed to less then 4% of their total thickness to remove the maximum amount of residual materials from deep within the product. This vital step improves durability and comfort by removing residual soaps, curing agents, and proteins that could cause premature softening of the product.
Step 6 - Dry
Mattress cores and pillows are then transferred to specially designed dryers that maintain the perfect shape while completing the curing process. After drying, each and every product is automatically conveyed to special areas for quality control testing.
Step 7 - Test
All of our pillows are weighed and hand inspected before being sorted by size and firmness prior to final finishing and packaging. Every single mattress core undergoes our exclusive 9-point test to ensure product firmness consistency from head to toe. This ensures tat a customer is getting the same mattress they fell in love with.
Why Tatalay?
So why should you be asking for Talalay latex? Because you should feel free of the burden of over-processing and of chemical enhancements and instead feel that every aspect of your mattress decision is benefitting not only your health and well being, but also of the environment. Tranquility Mattresses takes every step to ensure that our mattresses meet the highest standards for environmentally friendly production and pass these advantages to you.