I am not sure if everyone looking for latex realizes that there are two different ways to produce Dunlop process latex. The original Dunlop process latex was produced as far back as 80 years ago. Dunlop process latex has traditionally been produced in molds that yield one core at a time. There are now manufacturers that have developed the technology to produce Dunlop process latex on a continuous pour line. This enables these producers to make the equivalent of multiple cores or toppers at a time. Admittedly I was skeptical of latex being made this way, but after working with latex made on a continuous pour line, I have to admit that I am impressed with latex produced this way. There are two manufacturers in the US that use continuous pour, Mountain Top and Latexco. Mountain Top has the patent rights to use the continuous pour process to produce cores up to 7” while Latexco can only produce topper material up to 1.5”. Latexco can produce 3” product by doing what amounts to a double pour, by pouring an additional 1.5” on top of already produced 1.5” product. Mountain top uses a pinhole configuration that zones their latex by using less pinholes in the middle of produced latex cores, while Latexco actually can mechanically punch pinholes in their latex. Both products offer very consistent cores with very few air voids with cosmetically superior looking product.
There other real advantage is cost of production for continuous pour Dunlop process latex. By producing multiple cores or toppers all in one continuous pour, these products can be mass produced. Also, as compared to Talalay process latex that requires much more energy to produce, continuous pour Dunlop is typically at prices that are 10-15% less. Continuous pour Dunlop has a feel that is slightly like molded Dunlop and Talalay latex. Continuous pour Dunlop process latex is the most significant technological advancement made in years in the production of latex. This is the future latex as far as I am concerned. I expect the real growth in the sales of latex will be made this process. The reason I say this is because one of the impediments to greater use of latex has been the high cost of the product. It remains to be seen if this is true, but as a veteran of the latex mattress business, I expect this to happen. Consumers should be aware of this development and should not be afraid of mattresses made with continuous process Dunlop latex.