Sleep Amazing is proud to be able to offer the customer some of the highest quality products available. Many of our products are made with Talalay Latex, which is some of the finest latex ever made. We invite you to watch the video below from one of our component suppliers, Latex International (or you can continue to read below), so that you can get a better idea of some of the time, quality and effort that goes into producing the materials for our state of the art products.
 

IF YOU COULD IMAGINE THE PERFECT SLEEP ENVIRONMENT, WHAT WOULD IT BE LIKE?

Perhaps a soft, supple pallet that conforms to the shape of your body, and provides a cradle of support. A place where you could escape the pressure of the day and breathe easy. A relaxing refuge that refreshes the mind, restores the spirit, and revitalizes the body to face another day.
 

What if we told you this dream product really does exist, and is made in the USA? Our component supplier, Latex Foam International, which is located in the Naugatuck River Valley of Connecticut, has been creating superior sleep products safely and naturally for over 25 years. As North America’s only manufacturer of latex foam mattresses and pillows, their staff is proud of the job they do, and the products they help create. Everyone at Latex Foam International, from their engineers to their accountants, had a hand in the design of their new, state-of-the-art facility. All of their ideas and actions are measured against four priorities that permeate their daily operations: safety, quality, delivery and flexibility.
 

When they began to design and rebuild their facility, they decided not only to meet these standards, but to raise the bar. The result is advanced technologies and procedures that are so innovative that they have set the new world standard for manufacturing safety and efficiency, product quality, and world class service.
 

They produce their mattresses and pillows using the Talalay process. The Talalay process is an environmentally friendly production method that creates the world’s finest quality, most resilient, breathable, and consistent latex foam for mattresses, toppers and pillows.
 

From mixing the raw materials, to having a finished product ready to ship, the six step Talalay process takes about 8 hours to complete. Each step is carefully monitored and controlled by a sophisticated computer integrated manufacturing system and the talents of their experienced staff.
 

The Talalay process begins when raw latex, which is derived from the sap of the tropical rubber tree, is combined with soaps and curing agents in a stainless steel tank. Specific combinations are mixed to meet the needs and requirements of each customer. Raw materials are filtered twice before mixing to ensure uniformity in the end product.
 

A cooling system on the outside of the mixing tanks keeps the compound at a consistent temperature to eliminate variability in the process. Each fully automated tank is controlled from the touch screen panels throughout the factory. The system ensures an ideal mix each and every time by monitoring the consistency in the temperature, the mix time, and the viscosity. When required, the system will prompt the operator to conduct further tests, or to add additional ingredients.
 

The finished compound is then transferred through a network of pipes and filters to foamers in the computer controlled press room on a just-in-time basis. The press room is made up of four banks of twelve presses. Each bank has a dedicated robotic arm. The press room is designed with ample room for expansion and to be able to accommodate an additional bank of presses.
 

When the compound arrives at the press room, it is whipped into a foamy liquid and transferred to a robotic arm for injection into pin core aluminum molds. These molds create the unique aerated cell structure of the Talalay latex, and facilitate heat transfer during the curing process.
 

The robots measure and pour the liquid foam in a specific pattern that creates a uniform product. The pour pattern and the compound quantity can be easily adjusted for specific customer needs using any of the touch screen displays.
 

The Talalay process features two unique steps, vacuum and freeze, that creates superior consistency and feel in the finished product. When the pour is completed, the mold is closed and sealed. Air is extracted, and the vacuum is formed. This procedure distributes the liquid latex within the mold perfectly. Once the vacuum cycle is complete, the foam is chilled to minus 20 degrees, freezing the solid latex particles into place. Freezing prevents gravity from letting the particles settle at the bottom. Once frozen, CO₂ is introduced to allow the foam to gel.
 

Next, the foam is heated to 220 degrees to cure, allowing the latex foam particles to bind as it is baked into a solid state. Once the automated curing cycle is complete, the product is removed from the mold and transferred to a conveyor system. The conveyor automatically sorts the products for washing, drying, and final curing.
 

Touch screens allow the tracking of individual mattress cores and pillows all the way through to final quality testing. The first stop is a five stage washer which removes residual soaps and curing agents using fresh water. Mattresses are transferred to a two lane dryer, and pillows to an eight lane dryer. Each dryer is specifically designed to complete the curing process and to maintain the shape of the finished product.
 

After drying, every mattress and pillow is conveyed to special areas for quality control testing. Latex International, LFI’s mattress division, is the only manufacturer to quality test every mattress core in nine areas to ensure product firmness consistency. Based on the results of the compression test and the overall weight of the finished core, a unique ILD or “Comfort Rating” is assigned to every mattress core. A serial number is also assigned that will give the genealogy of each individual mattress core. This enables any potential issue found to be traced all the way back to where it began as a compound mix.
 

Each product is labeled with its unique serial number, weight, the nine pressure readings, the time and date it was tested, and the overall quality rating. After being placed in inventory, mattress cores are then transported to the fabrication area where they are cut and assembled according to customer needs. Special water-based adhesives are used that provide an extremely secure bond, while being environmentally friendly. Complete customization is available, including zones of comfort and support, layering, and patented edge support, as well as the combining of their premium Talatech® latex with their imported continuous process, Unilatex™.
 

In addition to their custom fabrication capabilities in Connecticut, LFI also operates a facility in California to better service customers in the western United States.
 

Finally, finished mattress cores are carefully packed and prepared for shipping to customers around the world. Their latex foam mattresses and pillows offer a unique feel and unique features. They conform instantly to the shape of the body for ideal support. They reduce areas of high pressure that cause tossing and turning, and they can improve circulation enhancing individual rest and recovery during sleep.
 

All of their mattresses and pillows are naturally anti-microbial, mildew proof, and dust mite resistant, have a breathable open cell structure, are exceptionally durable, boast the world’s finest quality, and they are made in the USA. By bringing together superior technology, experience and service, Latex Foam International is more than a component supplier. They have become the designers and manufacturers of the best latex mattress cores and latex foam pillows in the world. Every aspect of their organization has been designed with one basic goal: to live up to your highest expectations, and, go one step beyond.