2. Latex Foam Guide – A Guide to Comparing
and Buying Latex Bedding Products – Latex Mattress Sets,
Latex Mattress Pad Toppers and Pillows
The History and Development of Latex Foam
Natural Rubber made its official western debut in France around the year 1736, though the
miraculously waterproof character of rubber apparently also brought one man to court in
Portugal on the charge of witchcraft.
Nowadays few
would probably be
aware that Hevea
brasiliensis, the
rubber tree
commonly found in
Southeast Asian
countries as well as
some parts of Africa
and India, originated
in Brazil – as its
Latin name suggests.
Indeed, Brazil was
the original source
of commercial latex
rubber until the early
1900s. This market
having been
developed by the
British,
representatives of
the British
Government quietly
took thousands of
seeds to London 1870s,
which were later exported to Asia where they rooted well and grew vigorously.
Since then, techniques for rapid tree cloning, harvesting, plantation management, and processing
have been developed. Although it may not seem significant at first, the production of quality
trees and the skill with which they are tapped are extremely important. Poorly produced or
tapped trees may not grow properly, and will actually stop producing prematurely during their
production cycle.
3. How is Latex Used?
Latex has gained wide popularity throughout society due to its unique elastic properties, as well
as its water repellency and ability to recover completely when subjected to compression or
elongation. Oh, and those handy-dandy erasers! Latex rubber and its synthetic family have
revolutionized many industries, from mattresses, clothing, and bicycle and automobile parts to
rubber bands, canning jars, and
adhesives.
Of course, some of the initial
limitations of the product were
overcome in 1839 when Charles
Goodyear re-invented the
vulcanization process – giving
rubber the ability to maintain its
unique characteristics under high
and varying temperatures. This, in
turn, made it possible for both the
bicycle and automobile industries
to rise in global popularity, in turn
fueling the demand for high quality rubber products.
The demand for rubber of ever-increasing performance also led scientists to isolate the primary
chemistry of rubber and to reproduce it synthetically. In this one stroke, industrialists gained the
ability to formulate and craft specific types of rubber to meet the requirements of intended
products and the conditions in which they would be used.
Modern Latex Processing and Production Guide
The processing and production of rubber has progressed through numerous stages since
the 1800s, and matured from batch to continuous processing styles. Each step has
been intended to produce a better and more consistent product, with lower
materials and labor costs involved. There have also been divergent
methodologies developed in different sectors of the industry, aimed at
accomplishing the same end in different ways.
The two most common commercial processes are the dunlop
process and the talalay process. They are used for processing
natural latex or a blend, which includes natural latex. Since
the manufacturing of latex is over a decade old, many
additional processes have been developed. There are
numerous variations of each process, as well as alternative
processes, such as the Dow Process, for completely
synthetic rubbers, which will not be discussed here.
4. The Dunlop Process
After WWII, active interest returned to perfecting continuous processing of latex, improving the
qualities of the finished product, and reducing the expense. The Dunlop Process proved to be a
promising technological innovation which allowed the production of much more consistently
high quality rubber than was possible before. In this process, the liquid latex is first foamed, and
then gelled; and the latex batter is poured into the shape of the final product(s) while still in a
semi-liquid state. The gelling latex is then allowed to set before being vulcanized into its final
form. After vulcanization, the final steps, including washing and drying, take place. This
washing phase may help to reduce residues of the various chemicals used in this process at
different stages, for example chemicals used to maintain liquidity, to foam, to gel, etc.
The Talalay Process
The Talalay process was developed as an alternative to the Dunlop Process, in an effort to use
less chemicals in the processing. It is often portrayed as an all natural process or a process for
manufacturing all natural latex, but this is not so. Both the Dunlop and the Talalay processes are
used in manufacturing all natural latex, as well as blended natural and synthetic latex.
In this novel technology, the latex batter is also whipped, but the primary aeration or foaming of
the batter was achieved by chemical reaction or by reducing the ambient pressure – thus
encouraging natural liquids within the batter to evaporate, and gasses to expand naturally within
the batter, with minimal chemical intervention. Naturally, the aerated latex has to gel in the mold
before vulcanization and final washing.
Modern Talalay processing actually incorporates a quick-freeze of the aerated foam inside the
mould to maintain the homogeneous cell structure and density within the foam, and disallow
stratification and settling. Although proponents of Talalay processing claim that this type of
foam is more homogeneous, potentially less dense, and has superior qualities, critics argue that
the freezing of the latex batter weakens the latex matrix, and reduces the durability of the final
product.
5. A Guide to Natural Latex vs Synthetic Latex:
There are many interesting and valid
reasons why synthetic latex has been
developed for the bedding industry. Some
of the more significant considerations
include:
• Shipping: Natural latex must be
shipped from Southern Asia,
adding quite an expense.
• Increasing Demand: The global
market for latex had been
increasing faster than supply.
• Quality: The cultural and
governmental setup within rubber-
producing countries makes it very
difficult to control quality and
uniformity of the finished
products. Most natural products
have imperfections.
• Allergy: Reactions to natural
latex products;
• Control: Desire for more precise
ability to manipulate the feel,
weight and qualities of finished
product;
• Flexibility: A desire for much
finer gradations of density of the
finished product allowing for a
variety of uses.
Particularly with the ever-growing
domestic sales of latex bedding in the last
century, it made no sense whatsoever to
manufacture everything overseas. So,
while overseas production boomed,
domestic production also gained
momentum, offering many new bedding
options. Ironically, where 100% natural
latex products had potential allergy issues, synthetic latex products suddenly showed their own
side-effects – chemical off-gassing during use and toxic by-products when burned. Nevertheless,
blended latex products were also developed in order to harness the best qualities of both the
natural and synthetic varieties and eliminate unwanted characteristics.
6. Buyers must now be vigilant: marketing terms such “Latex Bed” or “Talalay Latex” do not
necessarily mean that the latex is 100% natural – and, in many cases, such terminology hides the
fact that the foam is actually an 80-20 or 85-15 blend of synthetic vs natural latex.
.
7. Latex: Allergies and Hypo-Allergenic Issues
Synthetic rubbers have gained in popularity and wide application particularly with the much-
debated topic of latex allergies – which can lead to anaphylactic shock and even death in severe
cases. There are varying theories about latex allergy, with some claiming that it is the proteins of
natural latex, or the chemical residues from processing, that are the real cause of the sensitivity.
8. Latex, the milky liquid harvested from trees and plants, is actually not exclusive to the well-
known Havea brasiliensis rubber tree. Indeed, there are many plants that produce latex to protect
and repair themselves when injured, and not all promote an allergic response. In the meantime,
or until hypoallergenic Guyale Latex is commercially developed, those with a latex allergy need
to be careful about latex products.
However, 100% Natural Latex foam as we know it today, by its inherent nature, reduces
or avoids the most common allergens associated with modern bedding materials without
chemical additives or synthetics. Due to thorough washing in final stages of production,
100% natural latex also reduces the tendency for aggravation of latex allergies by
significantly removing the plant proteins. Blended latex manufacturers tend to also make
this claim on the basis of the natural latex component in their finished products.
A word of caution, however: People with acute or life-threatening allergies should always
practice caution and seek the advice of their doctor or health professional.
The Latex Bedding Revolution
One of the ever-popular areas of use for latex is in mattresses and toppers. To get a sense of this,
just imagine emergent western cultures accustomed to decades of horsehair and other
unforgiving sleep surfaces suddenly discovering a soft yet firm rubbery surface that could be
slept on, something that was waterproof and warm, and at the same time yielding, smooth, and
elastic. Latex bedding proved to be a revolution.
Latex as a bedding material has evolved over time as the availability of the material, and
technological advancements, have produced ever-better varieties. Additionally, latex mattresses
and toppers have been relatively expensive until recent times. It has perhaps been the rise in
prices of comparable synthetic foam and bedding products that has reduced the gap to the point
where latex bedding tends to be only slightly more expensive; and that may, in part, be due to the
fact that they aren’t yet mass-manufactured in the kind of volume that would otherwise make the
prices equivalent.
In our time, natural latex is certainly considered very much of a luxury sleep surface in many
circles. However, natural latex is also very popular among the eco-conscious; as well as those
who cannot tolerate the chemical smells of synthetic foams, or who require the uniquely resilient
feel or firmness of latex for health reasons. Whatever the case, as mentioned above, not all latex
mattresses labeled as “talalay latex” or “latex mattress” are truly 100% natural latex. They can be
a synthetic combination.
To be perfectly clear, there will be synthetic latexes (“domestic latex”), there will be 100%
natural latexes, there will be blended latexes (sometimes called “Talalay” or even “natural”
without the “100%”), and there will be layered mattresses that may incorporate one or more of
9. these types of latex rubber. Each type has its advantages and disadvantages; its special qualities
and feel – and, in the end, such beds, toppers, and pillows were developed with people like you
and me in mind.
The Differences Between Latex Foams and Memory Foam
Both synthetic and natural latex products, generally being more dense in consistency, are most
often perforated like a pegboard in order to soften, lighten, and create enhanced airflow within
the finished product – even though the foam itself is foamed and aerated during production.
Memory Foam, a special kind of polyurethane foam, on the other hand, does not require
perforation, and performs admirably without. Developed originally by NASA Laboratories,
memory foam’s uniqueness lies in its ability to recover more slowly from body impressions (i.e.,
the sense of “remembering” body position) as well as responding to body weight and heat to
provide greater comfort and more even weight and temperature distribution.
Perforated Latex Pillow “Memory” Foam
Latex is known for it’s properties of orthopedic support. It is soft but also firm. In addition it
comes in an all natural variety. Memory foam on the other hand is all synthetic (though a natural
version is being developed). It is basically very softening.
Latex Pillows Guide
We’re all health and comfort conscious to some degree, and a more comfortable pillow – or even
one that helps reduce neck and head ache – is sought after nearly as much as the Elixir of Life!
So many designs and formulations have been created that it would be hard to tabulate them all.
Foam pillows might broadly be categorized as: 100% Natural Latex, 100% Synthetic Latex,
100% Memory Foam, and layered and blended combinations.
With ever-increasing awareness on health and the physical dynamics of body alignment, through
health sciences such as Osteopathy and Chiropractic, reduction of pressure points, proper
distribution of body weight on a sleep surface, and correct spinal alignment, have greatly
influenced the bedding industry. In terms of pillows, the cervical or contour pillow was
developed to help provide proper anatomic support for the head and neck.
10. Comparative Cross-Section View of Traditional vs Contoured Pillows
Latex Mattress Pad Toppers Guide
Latex toppers or mattress pads tend to be very
supportive and have a springy resilience. For this
reason, even a soft density latex topper can feel firm to
some sleepers. Latex is particularly good for general
support, support underneath a memory foam topper,
and for body weights over about 250 lbs. Because of
the durability and performance of latex, it makes an
excellent sleep surface.
It’s surprising what a few inches of latex can do for a
bed that isn’t otherwise comfortable. The soft and
springy resilience of latex provides soothing orthopedic
support, and helps to distribute body weight and reduce
pressure points. On top of that, perforations in the foam
itself help to increase air circulation and provide thermal distribution for better night time
comfort. Best of all, modern production technology involves washing the finished (natural latex)
product to help reduce or eliminate the plant proteins that may cause or aggravate allergy.
With synthetic latexes or blends, every day may bring an ever greater range of density and feel,
allowing the really discriminating sleeper to choose what suits them in a very meticulously
precise way. Particularly with blends, the topper may possess unique properties that provide an
unmatched sleep experience – for just the right person.
Latex Mattress Guide
Latex mattresses probably come in as many varieties as Ben & Jerry’s ice cream, in part because
they have been presented as a luxury item, and in part because each of us has his or her own
definition of what “comfortable” is. Some mattress manufacturers are even beginning to allow
independent customization of the mattress.
11. Contemporary choices include a range of mattresses from handsome tight-tops to luxurious
pillow-top styles; 100% natural latex mattresses, 100% synthetic mattresses, and sometimes
combinations of natural and synthetic
latexes – each with added comfort
layers of wool, cashmere, SuperSoft
foam, or polyester fiber, and
different thicknesses, sizes, and
shapes of the basic mattress or bed
set. Each will be covered in a
handsome or even elegant fabric
made of natural, synthetic, or
blended fibers.
When it comes to the general term,
“latex mattress” it is best to be
aware of the fact that many stores
will only tell you that their mattress
is “Natural Latex”, “Talalay latex”,
“Dunlop latex”, or merely “Natural”
or “Latex” – as if such a label will hypnotize you into accepting that their mattress is exactly
what you were looking for without ever telling you the full story. This would probably only be a
concern if you require a truly 100% natural latex mattress or have a particular allergy or
sensitivity.
The 100% natural latex mattress will generally be between 6” and 14” deep, and may be
anything from pure natural latex with an organic removable cover all the way to density-layered
pure natural latex wrapped in organic wool, with a cozy pillowtop, and adorned with elegant
woven fabric. Such luxurious covers are often quilted for added comfort, and to help keep
delicate layers from shifting.
The most common densities for
latex are soft (4.7 lbs density,
16 – 18 IFD) and medium (5.3
lbs density, 28 – 30 IFD),
though some manufacturers may
utilize higher densities for the
core of their mattresses. If
variable comfort and support is
important, multiple layers of
different densities might be the
way to go, as it provides the
best of both worlds.
In the realm of combination,
blended, or “domestic” latex
mattresses, the mattress will often begin with a core of high density polyurethane foam for
