Originally, in the manufacturing phase,latex rubber is composed of minute rubber particles dispersed in water. The liquid is whipped into foam, weighed, and then dispensed into a mold by a mechanical robot. While in the aluminum mold, thousands core pins first freeze the cell structure, then transfer curing heat into the foam. Through this unique process, our latex foam mattresses get their pin-core construction and superior cell structure ... which ventilates and insulates the mattress. Hence, you're cooler in the summer, and warmer in the winter.
After the wet foam mattress is stripped out of the mold, it is delivered to the washing unit. Four banks of weirs then pour hundreds of gallons of cleansing water, per minute, over each core. High-pressure rollers squeeze each core to flush away any residual soaps and bring each core to a semi-dry state. The washed cores are then steam-heated in a pressure-circulated, 120' long hot-air oven for crying. Electronic monitors conditionally check to make sure optimum drying conditions are maintained. This phase gives the mattress its longevity and continue comfort.
Each mattress is classified for degree of firmness after fresh-air cooling. Data is gathered by electronic load cell and then a computer rates the compression of the mattress core using the "American Society of Testing Materials (ASTM)" standards. Automated and visual inspection tests are run through the entire manufacturing process. Samples from each lot then undergo complete testing for flexibility and durability. To measure the equivalent of ten years of use, our impact tester subjects each sample to more than 15,000 impacts during its 24 hour test. This ensures a consistent, high-quality mattress that will keep its resiliency for years.
