ELECTROPEDIC ADJUSTABLE BED FACTORY
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Step 1: Compounding
Latex Foam International (LFI) is the only latex foam manufacturer in North America that employs the Talalay process. This process, driven by leading edge technology in the company’s state of the art Connecticut facility, generates the world’s finest quality, most resilient, breathable, and consistent foam for mattress cores, toppers, and pillows. The Talalay latex foam manufacturing process is a six-step procedure, which includes the following processes: compounding, whipping air into foam, pouring foam into a mold (with more foam = higher density = firmer product), pulling a vacuum (enabling foam to occupy the entire volume of mold), freezing (locks foam structure), injecting CO2 to gel foam (changes liquid to solid), heating (which solidifies durability and resiliency), de-molding core/pillow, washing, drying, inspecting for quality and fabricating.
Here are more details on the six primary steps:
1. Compounding: In the first step, synthetic and natural latexes, soaps and rubber curing agents are mixed together in a water cooled, stainless steel mix tank to create latex foam. Using computer automation technology, an operator mixes the batch. After all materials have been mixed, the operator conducts quality checks on PH, viscosity, and temperature to ensure that consistent compound is delivered to the molding process. The liquid latex foam is now automatically transferred to the pressroom through a computer-monitored pipe and manifold system. LFI’s system software automatically determines to which mold to send the compound.
2. Molding: Once in the state of the art, computer-integrated pressroom, the mixed latex foam compound is injected into an aluminum mold. This mold contains pins that create LFI’s unique aerated cell structure and facilitate heat transfer. Robotic systems distribute the mixture evenly to ensure consistency in the finished product. Once distributed evenly in the mold, a vacuum is pulled to completely fill the mold cavity with foam. The foam is then frozen in the mold and CO2 is introduced to the foam. Heat is applied to cure the foam to allow the latex particles to bond as the mattress core or pillow is baked into a solid state.
3. Washing: Upon completion of the molding process, the latex foam is placed on a conveyor belt and put through a large washer to rinse and remove soap residue and improve product durability. LFI puts each of its products through a five wash/squeeze cycle process, unique in the industry.
4. Drying: The mattress core or pillow is then transported by conveyor belt to a dryer. The core or pillow bun is slowly run on another conveyor belt through the dryer, which evaporates the liquids to finalize the curing process.
5. Quality Testing: Latex Foam International’s new facility boasts a state of the art quality control check system. In this rigorous testing process, the mattress core is placed on a belt and put through an exclusive nine-point pressure/firmness test to ensure that all cores meet stringent quality standards and that there is even support across the mattress. Pillows are hand-inspected for visual and physical defects, as well as individually weighed to ensure firmness meets exact specifications.
6. Fabrication: Cores are transported from the core bank to the fabrication area on a just-in-time basis. Here, the core is cut and constructed to the appropriate size. When larger core sizes and heights are needed, smaller cores are affixed with environmentally sound, water-soluble glue.
Quality Focus at LFI: Latex Foam International has embraced the six-sigma methodology to drive continuous improvement throughout its order processing and manufacturing processes to ensure customer satisfaction. In addition, LFI has partnered with Siemens, who has provided a state of the art automation and manufacturing execution system, based on an array of manufacturing technologies and electrical infrastructure products. The system also includes manufacturing execution software that automates factory floor operations and integrates the manufacturing processes with back office functions. The Talalay Latex Foam manufacturing process creates a product that provides many benefits. LFI’s latex foam …
… gently conforms to a person’s movements, providing correct, comfortable, support to head, neck, back and spine
… is naturally resilient, so it keeps it’s shape night after night
… is inherently hypo-allergenic and anti-microbial, so common germs, bacteria, and mildew cannot develop
…. features a galaxy of inter-connecting air channels that provide a natural ventilation system, keeping the mattress, fresh, dry, and cool.
Step 2: Molding
Step 3: Washing
Step 4: Drying
Step 5: Quality Testing
Step 6: Fabrication
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