A measured amount of slightly foamed latex is poured into a large fixed mould to only partially fill it. The lid is then sealed and the latex is expanded by vacuum to completely fill the mould. As soon as the latex has filled the mould it is ‘held’ and prevented from collapsing by rapidly dropping the temperature to -30°C and freezing it solid.

At this point, carbon dioxide gas is passed through the latex and the temperature raised to 115°C, which sets and vulcanizes it.

After which the lid of the mould automatically opens, and the product is stripped and placed on a conveyor.

The latex block or pillow is transferred first through a washer to rinse out any residual detergents and impurities before passing through a mangle to squeeze out the water. Every molding is washed in fresh water by passing under a perforated roller that forces water from the wash bath, by suction all the way through the latex. The wash water is continuously refreshed and used water is taken to a treatment plant to remove zinc and nitrogen compounds before releasing into public drains. The washing process ensures The healthiest sleeping conditions by removing all residual elements that may give rise to odor, allergies or bacterial/fungal growths

The product then travels through a system of overhead dryers prior to reaching a physical testing station. Every latex block and pillow is individually tested to ensure it meets the required specifications for density and hardness, prior to dispatch