Dunlop vs. Talalay Latex Manufacturing Process

Let’s Compare latex foams.

Talalay and Dunlop are each a manufacturing process for creating latex mattress cores. Dunlop and Talalay can be layers, toppers and pillows too. They are not types of rubber. We want you to make that distinction. Don’t make a potentially costly decision. Calling latex Dunlop or Talalay does not give any indication of whether it is botanical, blended, or synthetic. Retailers can cloud this information, and sometimes charge a premium for lesser quality products. Stay informed and ask the right questions.

The more important factors in getting the best value are:

• Is the latex botanical, blended, or synthetic (Styrene Butadiene or SBR)?
• How much of the mattress is actually botanical latex and how much is other materials?

Botanical latex comes directly from the rubber tree (Hevea Brasiliensis). This tree only grows within about 15 degrees of the equator. All natural rubber comes from this area. Botanical latex is the longest lasting, most durable material used for mattresses and does not have added chemical in which cause off-gassing. Most consumers call this natural latex. However, the industry often calls a blend of synthetics and botanical latex “natural latex”……What?

Synthetic Latex

The creation of synthetic latex (SBR) was prior to World War II. During the lead up to the war there was limited access to real rubber. Petroleum is the source of both styrene (plastic) and butadiene. Some mattress manufacturers and retailers refer to SBR made products as being “natural” latex, suggesting that petroleum is a natural product, and therefore the end result is also natural. Botanical latex is very different. SBR products have the tendency to break down like polyurethane foams; not keeping their shape like botanical latex. SBR also off gasses because of the petroleum content.

The mattress industry has very few regulations. So, manufacturers can call all synthetic latex, all botanical latex, or a blend, many things. Mattresses can also contain as little as an inch of latex, (often synthetic), laminated to a “soy” foam core (polyurethane). This is the most common type of “latex mattress” on the market and is a recipe for a very temporary sleep surface. This can be hard to ascertain from the salesperson or the advertising for the mattress. Often the promoter of the product relies on the consumer’s lack of knowledge. “This mattress is Talalay/Dunlop latex”, is often a selling feature. More importantly, they should address how much tree rubber latex. Deserve to know if it is real botanical rubber, synthetic or what blend.

The Dunlop Process

The Dunlop latex manufacturing process involves large metal molds (think of an oversized waffle iron) filled completely with whipped liquid latex. And then they heat molds throughout with thermal pins. The finished product is a latex core. The heating elements leave a thin vertical void. Therefore, it is sometimes referred to as pin-core foam. This process yields a solid, durable product that has been used in mattresses and upholstery since the 1920’s.

The Talalay Process

Developed in the 50’s, the talalay latex manufacturing process uses less liquid latex to produce the same depth of core. Here they use vacuum sealed metal molds. Whipped latex partially fills a mold. They apply a vacuum. The whipped latex expands to fill to space. It is then freeze-dried in place to set. A lighter weight foam that feels firmer than a correspondingly heavy dunlop results. The lighter weight is because there is more air and less rubber. The Talalay process is more often used as the cushion layers on top of beds. Because it is lighter weight, there are narrower cell walls. Talalay produced latex breaks down faster than Dunlop processed latex because there is less raw material.

Non-rubber producing countries are the primary source of Tally latex. That’s because they have to import all of the raw latex to make the foam. Manufacturers need to get the most foam out of the material they import.

Botanical Dunlop Cores

Dunlop cores offer a better, longer lasting support system for mattresses, a fact evidenced by their continuing use and popularity since the 1920’s. Softer, cushioned layers can be either Talalay or Dunlop processed latex depending on the durability preference of the consumer. The purest process and materials are Botanicore™.  Because we have a trademark, you can quickly discern the purest latex.

Botanicore uses a modified version of the dunlop latex manufacturing process. Less accessible, and more exclusive than the other types of latex, Botanicore™ process latex is a balance of consistency and durability.    Utilizing an open mold pouring process, there are no voids, no patches, no glued-up sections.  To avoid having a firm and soft side, the latex is vulcanized with the mold vertically oriented. Botanicore™ uses no synthetic or blended latex and the mattress cores are molded to size without glue-ups or patches.

Take a look at our selection of Latex Mattresses, all of which are made with Botanicore™ all natural, chemical free botanical latex.