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The Two Main Processes Of Latex Mattress Production Explained; Dunlop vs Talalay

February 28th, 2008

When it comes to the production of latex mattresses, two main processes are used. The Dunlop process, which is the oldest form of latex production still used today, and the Talalay process, which is a newer process. Both processes offer advantages, and in many cases, the production method is simply a matter of personal preference for consumers.

At Rocky Mountain Mattress, we strive to make sure our customers have access to all of the high-quality products they seek. That’s why we offer latex mattress products made via the Dunlop process and those made using the Talalay process.

Overview of the Dunlop Process

The Dunlop process is the most common method of producing mattresses and other products made from natural latex. In this process, the serum is collected from rubber trees, then frothed in a centrifuge. The material is then poured into a mold and baked at a low temperature. As the latex bakes and begins to firm, particles and sediments tend to fall and settle at the bottom of the mold. Because of this, products made through the Dunlop process often have one side – the bottom – which is somewhat firmer.

Around the world, the Dunlop process is the most common method of latex production. Latex products made using the Dunlop process are typically more dense than those made using the Talalay process.

Overview of the Talalay Process

The Talalay process of latex production is a somewhat more modern means of production, though with the advanced method comes a higher cost of production. Once extracted and prepared, the latex compound is ready to be poured into the mold. Once the latex material has been poured into the mold, the mold is sealed off. Air is then vacuumed from the mold, which is designed to evenly distribute the foamy latex material inside the mold. This leads to an open-cell, consistent end product.

Once the air has been drawn from the material, the mold is flash frozen for stabilization and the lock the latex product in place.

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