The story starts with mother nature. In the forests of Kerala, India, rubber trees produce a milky, viscous sap called latex. The process of drawing latex from the soft barks of rubber trees is called ‘tapping’.
Deep grooves are made in the soft bark with hooked knives. We are careful not to make them in a way that harms the growth of the tree. The sap then oozes out of these grooves. At the end of the groove, we place a container to collect the sap.
The process of tapping can be cut short when the oozing halts, which can often happen within six hours. However, the beauty of these trees is that we can immediately make new cuts in their barks to access their bounty once again.
Tapping rubber trees for their sap must be done when there is no direct sunlight. Sunlight can cause the collected latex to turn hard. Tapping is carried out at night or in the wee hours of the morning.
To give you an idea, tapping twelve acres of rubber trees for a whole day would yield just enough latex to make one queen-sized latex mattress.
Don’t worry, no trees are harmed during the process. Interestingly, the sap in the rubber trees get replenished quickly. What more? The trees actually reduce carbon dioxide in the air by a huge margin. Hence, cultivating them is a huge boon!
Latex has to be shipped to the processing plant immediately after its drawn out, on the same day. This helps us keep the liquid fresh and avoid coagulation. After all, we manufacture only the best for our customers
At the plant, the latex is sieved into large tanks. This ensures that the latex is free of particulate matter or coagulations. These tanks act like industrial-strength blenders. They whip the latex into a viscous paste.
Now it is time to use the moulds! We use a process called the Dunlop Method, which can be traced back to at least a century. It is considered the oldest latex mattress manufacturing process. The latex foam from the previous step is poured into special moulds. The vulcanization process follows, which consists of the moulds being sealed and heated. This process ensure that latex gets the right balance between firmness and softness. The pin core technology used helps create an opportunity for healthy air to flow through the mattress.
Once the latex is removed from the mould, we spray water to cool and clean the mattress. Then we bake it in a special oven to ensure there is no extra moisture.
The end product is firm yet soft, comfortable, and just the right texture for you.
We are committed to shipping out great quality products for our customer. We undertake manual and computerised testing of the mattress produced.
We compress different parts of each mattress and feed the data into our computers This ensures that only those with an acceptable & pleasant level of stiffness make it through the quality inspection.
Testing for durability is equally important for us. We take one mattress per batch and place it in a barrel. This rotates for several times, to reproduce the conditions of someone lying on the mattress. In this way, the barrel rotations are mimicking the movements of someone moving around on the mattress. This goes on for hours and hours. The number of rotations before the mattress begins to deteriorate gives us a clear picture of its durability and thus the durability of all the mattresses in that batch.