| 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. |
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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.
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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)
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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. |
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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. |
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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. |
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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. |