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The following six step process is commonly found on Latex mattress reviews and information sites.
After the rubber is dripped from the trees in the rain forest the first step can begin.

1. Step #1- Material Compounding: A Synthetic and natural latex mattress, begins when latex, soaps and rubber curing agents are mixed together in a water cooled, stainless steel mix tank to create latex foam. This process uses computer automation technology, while an operator mixes the batch. After all materials have been mixed, the operator conducts quality checks on PH, viscosity, and temperature to ensure that a consistent compound is delivered to the material molding process. The liquid latex foam is now automatically transferred to the pressroom through a computer - monitored pipe and manifold system. The computer software system automatically determines to which mold to send the compound.

 

2. Step #2- Forced Molding: Once in the state of the art, computer - integrated pressroom, the mixed latex foam compound is injected into an aluminum mold. This mold contains pins that create a unique aerated cell structure and facilitate heat transfer. Robotic systems distribute the mixture evenly to ensure consistency in the finished Latex mattress product. Once distributed evenly in the mold, a vacuum is pulled to completely fill the Latex mattress mold cavity with foam. The Latex foam mattress is then frozen in the mold allowing for the CO2 to be introduced to the foam. Heat is applied to cure the foam in order to allow the latex mattress particles to bond as the mattress core or pillow is baked into a solid state. (To the untrained eye this process looks a lot like baking a cake)

 

3. Step #3 Latex Foam Washing: Upon completion of the forced molding process step, the latex foam mattress is placed on a conveyor belt and put through a large washer to rinse and remove soap residue as well as to improve the latex mattress durability. Each latex mattress is put through a five wash/squeeze cycle process.

4. Step #4 Latex Foam Drying: The latex mattress core or pillow is then transported by conveyor belt to a dryer. The core or pillow bun is slowly run on another conveyor belt through the dryer, which evaporates the liquids to finalize the curing process of the latex mattress.

5. Step #5 Mattress Quality Testing: The quality tester uses Latex mattress reviews and information on the previous batch to determine backing techniques for the next batch of latex mattresses. In this rigorous testing process, the Latex mattress core is placed on a belt and put through an exclusive nine-point pressure/firmness test to ensure that all cores meet stringent quality standards and that there is even support across the latex mattress. Pillows are hand-inspected for visual and physical defects, as well as individually weighed to ensure firmness meets exact specifications.

6. Step #6 Design Fabrication: Latex mattress cores are transported from the core bank to the design fabrication area on a just – in - time basis. Here, the latex core is cut and constructed to the appropriate size latex mattress or latex pillow. When larger core sizes and heights are needed, smaller cores are affixed with environmentally sound, water-soluble glue.
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