Archive for July, 2010
Producing a talalay latex topper
July 13th, 2010 | 
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Latex Topper by Rocky Mountain Mattress
Latex mattresses and Latex toppers have become some of the most popular products on the market. Some customers have appreciated the health benefits associated with talalay latex mattresses. Some customers prove their loyalty due to the product’s ‘green’ characteristics. Whatever your reasoning, these products are sure to become a fast favorite of yours.
Latex toppers are known to be longer-lasting than the memory foam toppers. Rather than being composed of metal coils that can create pressure points, talalay latex mattresses are made of 100% natural latex. Although the talalay process is extremely intricate, it provides high-quality latex materials.
The main processing steps include: compounding, molding, washing, drying, quality testing, and fabrication. Each step is vital in creating resilient and consistent latex products. Technology is the main ingredient for creating talalay latex products.
During the first phase of processing, compounding, several products are mixed together to create a foam-like substance. These products are, namely, natural liquid latex, synthetic liquid latex, rubber curing agents and soap. All four products are mixed together using computer technology. Once the mixture has been whipped into a foam-like substance, it is tested. The temperature, pH levels and viscosity has to be exact in order to move forward with the manufacturing process. If these levels aren’t exact, the mixture is again whipped until it is pristine.
After the mixture has been whipped into the desired consistency, it is moved via specially designed pipes into the mold. Each pipe is monitored with a computer system to ensure that certain elements, such as the product’s temperature, remains intact. Each aluminum mold contains thousand of pins. Once the mold has been closed, the pins are injected into the mixture to create and ensure an aerated cell structure. The pins also serve another very important purpose. Heat is transferred through each pin. This sub-step of the molding feature allows the mold to be filled evenly. Then, a vacuum is introduced. The vacuum allows foam to entirely fill the mold. From here, carbon dioxide is used to ‘flashfreeze’ the product. Immediately following, heat is again used to set the material. Heat allows the latex to bond and form a solid and consistent structure.
Once the latex has been cured using heat technology, it is washed. The washing process ensures and improves durability. This step is similar to a vehicle going through a car wash, meaning that the latex is placed on a conveyor belt and washed.
The fourth step of the talalay process is the drying stage. The product is still on the conveyor belt. The conveyor belt moves slowly under the dryer to dry any excess water particles. The drying phase is also the final curing phase for the talalay product.
As with any product, the latex now transitions into the quality testing phase. The quality testing phase is rigorous, so as to ensure optimal quality and endurance. The latex firmness is tested and retested, along with the pressure. Some companies prefer to complete this stage with computers. Others complete quality testing by hand. Some even use a combination or computer testing and hand testing.
The fabrication phase is the final manufacturing phase. Each latex core is cut to size. In some instances, such as when a larger bed is ordered, several smaller core pieces are cut and a water-soluble glue is used to unite each piece.
All Natural latex mattress toppers are becoming more and more popular because of their environmentally sound manufacturing process and due to the natural nature of the product itself. Latex is automatically more breathable, resilient and longer-lasting than any other product on the market. They come with a wide array of benefits as well.
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