Even wonder how our Zaanta mattresses are made? Well, our unique manufacturing process is quite an interesting one – as it involves using no toxic chemicals or synthetic materials.
1 - Collect
Early in the morning, the tappers use a metal gouge with a sharp tip to make a shallow cut in the outer bark, at a downward angle, to winding ribbon around the tree. This opens the network of continuous latex vessels that spiral around the tree without harming it. The collected milk contains water, latex and other natural impurities.
Because the latex and water ratio varies in each tapping session, the rubber milk is then run through a centrifuge to balance the ratio and remove any impurities.
2 - Mix & Batter
Natural latex sap, or serum, is mixed with a tiny amount of natural ash (3.5%, with zinc oxide), before it is whipped into a froth in a centrifuge.
One of the differences between organic dunlop and natural dunlop latex is that the centrifuge plant must be certified by an organic agency. Our manufacturer owns the plants and is certified by GOLS (global organic latex standard).
3 - Mould Fill
The air filled foam is then pumped into large 6-inch deep aluminum molds (very similar to an oversized waffle iron). Latex foam is a poor conductor of heat (which is great for a mattress), so ‘pins’ are present in the mold to help heat and cool the foam.
4 - Bake
The mold is closed and then passed into large, circular ovens and heated to 350 degrees Fahrenheit for one hour.
5 - Wash & Dry
The resulting latex foam is then completely submerged (rather than just being rinsed) in several tanks with fresh water, before being squeezed to just 6 millimeters between steel rollers. This helps prevent allergies by extensively washing away any free proteins. The latex core then processes through industrial dryers.
6 - Quality Control
Quality control testing is done to ensure product firmness and consistency so that the natural latex performs.