What is the Dunlop process?

Dunlop is the original manufacturing process for latex foams. It was first developed way back in 1929, and the process has not changed much since then. This is the basic process for Dunlop latex: Liquid latex extract is mechanically whipped to form a frothy foam. The frothy material is placed in a mold.

What is dunlopillo made of?

A Green Nights Sleep Our Dunlopillo latex is produced from the sap of rubber trees and contains naturally occurring anti-allergenic, anti-bacterial and anti-microbial properties. Latex is one of the most eco-friendly mattress fillings. Latex rubber trees purify over 90 million tons of carbon dioxide each year.

What are the different process for the manufacture of latex foam?

The Talalay process is a method of producing molded pieces of latex foam rubber. A liquid latex rubber base is introduced to a closed mold and is then vacuumed of air. The mold is then frozen to stabilize the cell structure. Carbon Dioxide gas is introduced and the mold is heated to cure the rubber.

Where is Dunlop latex from?

It originates from rubber trees; actually from their sap. These rubber trees (Hevea Brasiliensis trees) are typically found in South America, and have a 25-year lifespan, making them highly productive for obtaining liquid latex through their sap. The Dunlop process, as mentioned, was started in 1929.

How is the Talalay process different from the Dunlop process?

The Talalay process is a more energy intensive process of producing latex foam. Many steps of the Talalay process are actually quite similar to the Dunlop process. As with Dunlop process foam, the latex is foamed and poured into a large mold.

How does the Dunlop process for latex foam work?

How the Dunlop Process Works: The Dunlop production process is the most energy efficient method of producing latex foam. While the latex is in liquid form it is foamed and poured into a mold. The mold is then closed up and placed on a conveyor belt. The mold is then moved on the conveyor belt into a vulcanization oven.

When did way huge move to Dunlop Manufacturing?

Jeorge Tripps launched Way Huge in 1992. In late 1999 the company closed its doors when Tripps went to work for Line 6. In 2008, Tripps and the company moved to Dunlop Manufacturing and resurrected the Way Huge line, including the Swollen Pickle (a fuzz), Pork Loin (an overdrive), Fat Sandwich (a distortion), and Green Rhino (another overdrive).

Why is the Dunlop vulcanisation process so slow?

The traditional Dunlop vulcanisation process uses steam as the heating mean to activate the cross-linking reactions of polymer chains. Foam, having plenty of tiny air bubbles within, is by nature a poor thermal conductor and therefore letting heat soak into thick mattress core or pillow molds is a slow and inefficient process.