The Dunlop Process:
Compounding – Natural latex, soaps and rubber curing agents are mixed together in a water cooled, stainless steel mix tank.
Mixing: – Compounded latex is sent though a machine to mix with air for the foaming process.
Moulding – Latex foam is injected into aluminum moulds. This mold contains pins that create a unique aerated cell structure and facilitate heat transfer. The lip seals on the moulds create a vacuum when closing the mould enabling the latex to distribute evenly and completely fill the mould cavity.
Baking – Heat is applied to cure the foam to allow the latex particles to bond as the mattress core or pillow is baked into a solid state.
Washing – Once the mattress and pillows are solidified they are stripped off the moulds and washed. This removes the soap residues and any other chemical and improves product durability.
Drying – The mattress core or pillow is then transported by conveyor belt to a dryer. The mattress core or pillow is slowly run on another conveyor belt through the dryer, which evaporates all the water.