How latex foam is made?

Experts at every step of production

The Dunlop Process is an eco-friendly production method with natural, biodegradable ingredients from renewable resources and water-based raw materials: natural latex, air, and water.

Compounding

100% Natural latex is extracted from the tropical rubber tree, like tapping a maple tree for syrup. 100% Natural latex, soaps, and rubber curing agents are precisely mixed in a temperature-controlled tank. Quality checks are performed on Ph, viscosity, and temperature.

Molding

The compound mix is injected into an aluminum pin core mold. The pins create our unique aerated cell structure.

Washing

Unlike other latex manufacturers, Pattani Industry washes every mattress core and pillow. The latex core is removed from the mold, placed into the washing machine, and rinsed with fresh water. Freshwater washes away residual soaps, curing agents, and proteins. During the washing process, the products are squeezed to less than 40% of their total thickness to remove the maximum amount of residual materials, which cluster deeply within the product. This vital step improves durability and comfort by removing residual soaps, curing agents, and proteins that could cause premature softening of the product.

Drying

The Mattress core is transported to a microwave and radio wave dryer, completing the curing process and removing residual moisture. Pattani Industry is the only one in Thailand that uses high technology drying process.