The all natural latex milk is tapped from the sustainable rubber tree plantations in Indonesia and Malaysia, and then shipped to modern Talalay latex processing plants in England and the United States where strict quality control guidelines are met for consistency in quality and optimal latex mattress core performance.

Talalay and Dunlop are the two kinds of manufacturing processes of making latex cores. Royal-Pedic uses the Talalay method. It is important to point out that just because the latex core is Talalay or Dunlop does not determine how natural the latex is. Rather, what gets poured into the moulds determines the naturalness of the latex core.

Talalay process all natural latex mattress cores have the added benefit of providing more of a natural “spring” feel. Whereas the less involved Standard Process, or also known as the Dunlop Process latex has a more “dead” feel in comparison. Therefore, the Talalay latex actively responds to the body contours providing better comfort and added support.

Before the all natural latex is poured into the mould it is blended with a very small percentage of sulfur and zinc, which react as a binder, so the latex cells will form together. In the Talalay process, the latex liquid is poured into special custom made aluminum moulds, which are equipped with a large number of pins. In fact, there are approximately 2400 pins in each Talalay lid and pan mould for a queen size latex mattress core. The pins serve a dual purpose of helping transfer heat evenly to all areas of the latex core, so there is consistency in mattress firmness and feel, and of creating “pin-core” holes, which later assist in uniform drying and providing improved ventilation of body heat.

After the latex liquid has been poured into the Talalay moulds, the moulds are shut and fitted with a rubber gasket seal around the perimeter, then vacuum sealed and cooled to about -30 degrees Celsius (-22 degrees Fahrenheit). Carbon Dioxide gas passes through the frozen matrix, which causes the foam to gel. At this moment, the individual air bubbles become interconnected. It is in this freezing process that the molecular structure of the latex changes resulting in a latex core that provides more natural “spring” feel and better comfort.

Once the gelling is complete the mould is progressively heated to 110 degrees Celcius (230 degrees Fahrenheit). The heat induces curing, or “vulcanization” of the latex core. Finally, the Talalay process all natural latex cores are carefully removed from the moulds, washed in 4-5 rinsing processes, dried, and inspected.

In comparison, Dunlop latex cores completely skip the vacuum sealing and freezing of the latex step. Instead, the latex liquid gets poured into the mould, lid gets shut and it goes to vulcanization, removed, rinsed, and dried. While the Dunlop process is quicker and less expensive to make, it results in a lesser grade quality of latex core providing a more lifeless level of support and comfort.

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