Manufacture

Manufacture of cold foam

Our organic cold foam involves a high resilience (HR) foam material, which is created by using soya oil. In addition to the effect of an improved environmental record by using renewable raw materials this cold foam has a few more advantages. It is therefore certified in line with Öko-Tex® Standard 100 as a class 1 product. Its pH neutral value means it is suitable for sensitive baby skin. Furthermore the foam material is fire-resistant in accordance with FMVSS 302, California 117D. Therefore the material is fireproof without any additional fire resistant properties.

As the description ‘high resilience’ already suggests, in comparison with conventional foam materials, cold foam boasts a significantly higher elasticity which is coupled with longer durability. It is foamed up in the foam block process aided by air at low temperatures than for conventional foam material which is why the description ‘cold foam’ came about. Finally the block is divided up into suitable sizes during which complex carved out contours also become discernible. As the cold foam initially shows predominantly closed pores after the foaming process the opening of pores required for the mattresses is achieved by so-called ‘crushing’. The hardened foam block is compressed by rolling until the cell membranes burst. Unlike latex, cold foam has an irregular cell structure which gives rise to a homogenous distribution of the hard characteristics in the cross section of the block as well as improved elasticity.

Due to its open cell structure our organic cold foam is particularly moisture-absorbent and breathable. Of course various degrees of hardness can be created with this cold foam where the durability is still present to the same extent and with the same thickness.

Manufacture of latex

The latex which is used in our products is made up of a combination of natural latex and synthetic latex. Natural latex is mainly acquired by extracting it from rubber tree ‘hevea brasiliensis’ which is native to South Asia. A rubber tree of this kind can produce around between 50 and 80 grammes of rubber milk a day. Latex also owes its name to this optical similarity to milk which is derived from the Spanish word for milk. Our latex exploits the capabilities of the naturally occurring latex by combining it fully with synthetic latex.

The production process for this special latex comprises 9 hours. Initially the natural latex, synthetic latex and special additives are mixed with air to create a mixture full of air bubbles and an open cell structure.

This mixture is now put into moulds which have metal rods distributed evenly. This is the point at which the characteristic ventilation holes are created for the finished product. The filling quantity regulates the firmness of the finished foam in relation to the required comfort and support.

The foam is now distributed evenly by means of vacuum throughout whole mould and the air bubbles which have been closed up can expand accordingly. A homogenous cell structure is achieved in this way – the stamp of high quality.

Finally the mould is cooled to minus 30° C allowing the cells to go back to their original round format and the cell membranes to burst open. The broken cells combine with each other and in this way form the much-feted open cell structure which is required for the best possible ventilation.

The foam block is stabilised by adding CO2 and the open cell structure is permanently preserved.

Within the pre-vulcanisation process the mould is heated to 115° C and the foam then takes on its elastic characteristics. Now the material is hard enough to be taken out of the mould.

In order to improve the durability of the latex the block is washed. The block is put through a sprinkler system which washes off the extraneous material from the latex block. During this process the block is put under pressure to convey water into the depths of the latex and then out again. The result is a very clean product.

Now the organic latex is dried at 85° C for around 30 minutes and vulcanised again for a further 8 hours during which time the latex takes on its final characteristics.

The quality control process follows automatically on from the complex finishing process when the firmness of the block is measured at 15 reference points under controlled conditions. In this way we can ensure that only first class material is used and blocks which are unacceptable are automatically rejected.

Of course the finishing process of our latex allows for the production of differing qualities from soft to firm.

The combination of foams achieved in our mattresses (types 1-3) with various levels of firmness creates a specific tailored support. This segmentation offers an anatomically correct lying position in line with the principle of having the right material in the right place.