How is latex made? The production of chemical free latex used in products such as mattresses and pillows follows a process known as the Dunlop Process. This process involves pouring liquid latex onto a long conveyor belt, allowing it to go through a vulcanization — this gives the latex its ability to mold for a firmer product — and finally cooling so that the movements of the cells settle and make it thicker. Unlike flash freezing, this ensures that each product features a solidified, thicker quality throughout. As such, products produced with Dunlop Process are more durable than those created with any other method.
What is latex made of?
How is latex made? It all starts with the Dunlop Process, first developed back in 1929. The process begins with thick rubber sap that is whipped into a froth in a centrifuge before it’s poured into an open mold and covered. Then steaming begins and natural sediments settle to the bottom of the mold making the Dunlop layers slightly firmer on the bottom side for more support. With this method of vulcanization, latex mattresses are created in soft, medium, and firm varieties giving you plenty of choice when it comes to selecting your perfect sleeping comfort level.
SHOP BEST SELLING
Latex Mattresses
Shop The Category
MOONLIGHT ORGANIC MATTRESS
SHOP NOW
ECOSUPPORT PURE LATEX MATTRESS
SHOP NOW
COMFORT REST LATEX MATTRESS
SHOP NOW
ECOREST MAX LATEX MATTRESS
SHOP NOW
ECO PURE WOOL MATTRESS
SHOP NOW
COTTONX COPPER LATEX MAITRESS
SHOP NOW
What is latex made of?
For those looking for a perfect night's sleep, latex mattresses provide the ideal combination of comfort and support. Crafted from liquid latex through vulcanization, these mattresses come in several variations of firmness from soft, medium to firm.
How Dunlap Latex Is Made:
learn more about the manufactoring processDunlap Latex Technology:
MIXING
The process of crafting latex products starts in the temperature-controlled tanks, where precise formulas are carefully blended to create a unique and perfect compound.
VULCANIZATION
To create a unique latex foam, air is carefully incorporated into the mixture. This foamy compound can then be poured into molds or pinned plates before it undergoes its transformation in the steamy heat of vulcanization.
CLEANING
After the form is taken out of its latex sheath, it undergoes a watery purification to rid itself of soapy remains and chemical preservatives.
ROLLING
With a steady hand and focused effort, excess moisture is removed from the latex sponge by squeezing it between rollers.
DRYING
The drying machine then finishes off the job with its effective evaporating power, leaving this spongy material as dry.
MEASURE
Transform latex into custom-made cores of varying widths! Experiment with sponge layers of different thickness and density to generate unique, durable results.
Natural latex has a vast and intriguing history, starting with its origins in the Hevea-Brasiliensis tree - better known as the rubber tree. Rubber trees are native to South America but were spread around the world during 19th century due to their immense value. Nowadays, much of this precious liquid is harvested from Sri Lanka where it flourishes thanks to ideal conditions for growth creating an industry centered around natural rubber products.
If you're looking for a mattress that offers superior support and relief to your pressure points, look no further than latex mattresses. It is especially beneficial in areas where extra weight or strain can be felt such as the shoulders, back and hips - allowing even distribution of comfort across the entire body!
Dunlop Latex is the Natural, ideal choice for those with chemical sensitivities who want to sleep better. In addition to its high durability (lasting up to 20 years), resistance to heat and high elasticity, it does not off gas, is also naturally Hypoallergenic, Anti-fungal, Anti-Bacterial and dust mite resistant. As if the natural properties retained in this product were not enough, the way in which it is manufactured is also eco-friendly. Dunlop Latex
- 2 one inch latex cores
- 34-38 ILD - 85-90 Density
- Chemical Free.
- Superior Pressure Relief.
- Anti-microbial Dust mite Resistant.
From Latexco LLC
Our partner has access to the finest quality 100% natural Dunlop rubber latex from its strategic partner plantations in Sri Lanka and India assuring us the best quality material for our mattresses. Natural latex is manufactured from the sap of the rubber tree. It has many unique properties such as extreme stretching up to 200% resistance to heat, high elasticity and bio-degradability. Combining all these superior properties, our scientists have developed an ideal mattress to rejuvenate your body and give you comfortable sleep. Click here to see the technical information on The Futon Shop's latex.
Value of Natural Latex Extracted from the sap of the rubber tree, Natural latex foam has several superior properties, resistant to heat, 200% stretchability, high elasticity, anti-bacterial properties. Our latex sheets are washed in warm water, to remove all impurities make it a safe product and chemically free. Our curing system ensures that every mattress core is perfectly cured and evaluated for harness, permanent deformation, breaking stains, aging and density, ensuring that every core is world-class. The latex sheets have air holes to support your body curves. The pinholes in the latex core allows the mattress to breath and thus reduce heat build up while providing natural ventilation. Our Dunlop cores provide each sleeper with total support and an individual sleeping surface, making it highly unlikely you will be disturbed by your partners movements. Our latex cores mattress never need to be flipped and are naturally conforming to your bodies pressure points. Dunlop Process Open mould filling system essential for making our high quality 100% Natural Latex cores.I.L.D., " Indentation load deflection", is measured by putting a 15"x15"x4" specimen of foam in an indentometer and measuring the weight required to push the foam down to 25%, 65% and back to 25% of its thickness. Therefore, an I.L.D. rating of 10 lbs. at 25% means that it takes 10 lbs. to compress the foam 25%, 65% I.L.D. compresses the foam 65% and will have a higher figure, then it is brought back to 25% and this is generally the right I.L.D. rating. These days I.F.D, "Indentation force deflection", is sometimes used instead of ILD but means the same thing. We offer the following latex ILDS– Soft: 18-22, MMedium: 23-27, Firm: 34-38, & Extra Extra Firm 45-49 DENSITY - Lbs. per cubic foot is simply the DENSITY of the foam and is not related to I.L.D. at all. You can have a high I.L.D. on a low density piece of foam and conversely a low I.L.D. on a high density foam. The higher the density of the foam, the better the quality and durability of the foam. I.L.D. has nothing to do with the quality, it merely indicates the softness or the hardness of a piece of foam. We offer the following latex Densities–Soft: 70-75, Medium: 75-80, Firm: 85-90, Extra Extra Firm 95-100
- Compounding - The compounds are 100% natural latex, tapped from a rubber tree.
- Vulcanizing - Steam cure technique with design engineered thousands of stainless steel pin of the right size and shape give the most efficient vulcanization that makes our latex so comfortable and durable. These pins keep the natural latex characteristics undisturbed through the vulcanizing process.
- Washing - Multi-cycle washing method using drinkable quality water to ensure clean & pure latex mattress cores.
- Drying & conditioning - Drying & conditioning – A soft condition drying mechanism is used to enhance the natural feel of the product and eliminates all residual moisture.
Latex Bed Pillows
Latex Shiki's
- Learn more about Traditional Shikifutons
- Learn more about Shikibutons / Folding Foam Beds
Global Organic Latex Standard
- Mattress Manufacturing - What is a GOLS Transactional Certificate
- What Is GOLS Mattress Certification?
- Look For GOLS Certified Latex In A GOLS Certified Mattress
- Read about the Farm to Bedroom movement.
- Click to research other organic mattress ingredients.
- Click to browse through some great organic cotton mattresses.
- Click to read about How Long Does A Futon Mattress Last?.
- Click to read about Should You Buy A Organic Latex Mattress?.
- Click to read about Which Mattresses Are Best For Motion Isolation?.
- Click to read about How Is Latex Manufactured For Mattresses?.
- Where Does Latex Come From?.
- Click to read more about What Are Latex Mattress Densities?.
- Click to read about What Are The Benefits Of Latex As A Mattress Ingredient?.
LEARN MORE
Everything You Need To Know About Futons
