Dunlop and Talalay are two methods for manufacturing the latex foam used in bedding. Both methods use natural latex and can produce latex mattresses of soft, medium, or firm density.

Dunlop is the standard technology, developed in 1929, while Talalay is a relatively new method that is more complex, costly, and time-consuming. 

The production process always starts with mixing liquid latex with water. There are small amounts of other materials required for processing liquid latex into a solid form, which are necessary for all latex production. These are natural soaps, sulphur, gelling agents, and vulcanisation agents. When the latex mixture is ready, compressed air is used to make foam. The foam is then poured into a mould, after which the vulcanisation process begins. The latex foam is vulcanised at a temperature over 110 degrees for about 50 minutes. The finished mattress core is then taken out of the mould, washed, and dried.

The key difference in processing between the Dunlop and Talalay methods is the two additional steps in the Talalay technology: vacuum and freeze.

When the mould is filled with the latex mixture and then closed, the pressure inside is reduced to create a vacuum, which lowers the air pressure in the mould cavity while increasing the air pressure in the foam bubbles. As a result, the foam expands and fills the mould evenly, and the pressure inside the bubbles is driven to equalise over the entire latex block, leading to a very uniform density.

The key distinction is the freezing stage (-30°C/-22°F), when the round cells break open so they can connect with each other. Talalay latex is up to ten times more breathable than other foams due to these interconnected round cells. The water in the latex foam is then frozen, and carbon dioxide is injected. The freezing prevents the latex particles from settling at the bottom and transforming into a solid product. This means that the finished Talalay latex mattress has a very consistent density from top to bottom, as well as a lighter, fluffier feel. Talalay latex is made with one comfort zone due to its superior elasticity, as it adapts better to the shape of the body.

Because there is no freezing stage in the Dunlop process, the rubber particles settle at the bottom of the mattress while the liquid latex is gelling into its solid form, so there could be slight differences in the feel and firmness of the two sides of a Dunlop latex mattress.

Although the Talalay process takes four times longer and consumes five times more energy than the Dunlop process, the two additional process steps improve the feel, quality, and consistency of the finished latex, but at a high additional cost. 

Dunlop Latex Manifacturing Process

a.   The mixing of the ingredients (latex, soap, vulcanisation agents…) into compound
b.   Compressed air (necessary to make a foam)
c.   Continuous foamer
d.   Cleaning and heating of the mould
e.   Applying a special agent to be able afterwards to get the mattresses / pillows out of the moulds

1.   Filling the mould with the latex foam
2.   The mould closes and enters the vulcanisation oven
3.   Vulcanisation oven: steam at 100ºC
4.   The finished mattress / pillow core is demoulded
5.   Washing of the mattress / pillow core
6.   Drying
7.   Quality control (checking hardness, weight, visual control)
8.   Finishing
9.   Storage

Talalay Latex Manufacturing Process

a.   The mixing of the ingredients (latex, soap, vulcanisation agents…) into compound
b.   Compressed air (necessary to make a foam)
c.   Continuous foamer
d.   Cleaning and heating of the mould
e.   Applying a special agent to be able afterwards to get the mattresses / pillows out of the moulds

1.   Filling the mould with the latex foam
2.   Creating a vacuum (Specific for talalay process only)
3.   Freezing to -30°C (Specific for talalay process only)
4.   The mould closes and enters the vulcanisation oven
5.   Vulcanisation oven: steam at 100ºC
6.   The finished mattress / pillow core is demoulded
7.   Washing of the mattress / pillow core
8.   Drying
9.   Quality control (checking hardness, weight, visual control)
10.   Finishing
11.   Storage