Talalay method is the newer method of the two. It follows the same steps as the Dunlop method with only slight variations.
Here is how a Talalay Latex mattress is made:
Step 1: Liquid latex is whipped into a froth
Step 2: It’s partially poured into the mold. The mold is then sealed shut in a vacuum to help expand the foam.
Step 3: The latex in the mold undergoes a flash freeze process where Carbon dioxide is blown through the mold causing it to gel
Step 4: The frozen latex is then heated in an oven
Step 5: The resultant foam is then washed and air dried to remove any remaining moisture
The vacuuming process in the Talalay method allows for an even distribution of particles. The flash freezing makes Talalay foam lighter and fluffier in texture.
While the Dunlop method can produce huge blocks of foam that can be turned into a mattress directly.
The Talalay method can only produce smaller blocks at a time.
So, most Talalay mattresses usually contain several layers which are glued or stitched together.
It’s good to find out where and how the layers are attached together, to ensure you get a quality long-lasting mattress.