DUNLOPILLO: THE ORIGINAL LATEX FOAM
In January 1929, Mr E.A. Murphy, of the Dunlop Rubber Company III Birmingham, invented Latex Foam. It was the culmination of many years’ research and an invention that was to make the world a much more comfortable place.
The search for a technique to create foam rubber from liquid latex had preoccupied rubber technologists since the start of the century and it is doubtful whether those working on the project fully appreciated the significance of what they had achieved.
Today, latex foam is regarded as the supreme cushioning material and is widely used in bedding and furniture markets around the world.
One particular type of latex foam however, has established itself over and above all others – that material is Dunlopillo Talalay Latex.
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THE BENEFITS OF TALALAY LATEX
Pincore Latex, produced by the Talalay system, is characterized by the large number of pencil-shaped holes formed by the pins in the lid and base of the mold. Combined with the uniform, open cell structure of the latex foam, these pin-holes provide an excellent ventilation system that allows the product to breathe.
Notably, Talalay Latex pillows and mattresses have, for many years, proved beneficial to people allergic to more traditional fillings.
Dunlopillo International Talalay Latex is also highly versatile III that Its symmetrical structure allows it to be cut into intricate shapes without losing any of its natural resilience.
This makes it ideal for hand-building and splitting into sheets, although Dunlopillo International can supply sizes up to 150cms wide and 15cms deep in a single piece. Dunlopillo Talalay Latex is available in a variety of hardnesses, from SQ through to extra firm, catering for all sorts of applications.
No CFC’s are used during the manufacturing process, making it kinder to the environment. Resistant to bacteria, durable, resilient, well-ventilated and extremely comfortable, Talalay Latex is considered the luxury interior for furniture and mattresses.
Remember, all Dunlopillo International latex foams are thoroughly washed during manufacture in order to produce the best physical properties and avoid the risk of latex allergies.
THE TALALAY PRODUCTION PROCESS
A mix compound containing a blend of natural and synthetic latex is prepared. Soaps, sulfur and other ingredients are added and air is injected into the mix. The desired quantity of wet foam is then metered out into special aluminum molds with a large number of thin vertical pills which are necessary for efficient heat transfer throughout the product. After the mold has been partially filled with liquid foam it is closed, and sealed. It is then cooled and a vacuum applied which causes the foam to expand and fill the mold.The foam is then frozen by cooling the mold to -30°C, and carbon dioxide gas is passed through, which causes the foam to gel. It is this freezing/gelling operation which gives Talalay foam its superior structure compared with foams made by other processes. Once gelling is complete the mold is quickly heated to 110-112°C and vulcanization induced. After de-molding all products are thoroughly washed to remove soaps and other residual ingredients which have served their purpose and are undesirable in the final product. Finally, the products pass through a highly efficient forced-air dryer. This ensures that not only are the products completely dried, but that the exacting quality specifications. physical properties of the foam also meet exacting quality specifications.
RESEARCH AND DEVELOPMENT
Dunlopillo International is constantly researching new processes, materials and standards in its laboratories at Pannal. We are keenly aware of the ever changing marketplace and the need to investigate further uses for Talalay Latex through continuous product development and close liaison with our customers.
Investment in the latest profile cutting equipment has enabled Dunlopillo International to offer its customers a comprehensive range of contoured cushions, pillows and block.
This means that we can now virtually tailor-make a product to each customer’s requirements. Adhering to the strict flammability regulations of the furniture market III the UK, Dunlopillo International now leads the world in the production of fire retardant latex foam pillows, mattresses and block.
At Dunlopillo International we have developed the bagging of latex cores and sheets into polythene bags, which are then compressed into roll packs in order to compress the volume by around 50% – increasing the efficiency of shipping.
Dunlopillo International’s busy export department is committed to offering the customer a complete service, from order inquiries and price quotations through to an efficient all-inclusive delivery of the products, handling all necessary paperwork.
Our multilingual team regularly deals with customers in more than seventy countries worldwide, ensuring that each order is closely monitored to meet the required specifications and lead time.