The Dunlop production process is the most energy efficient method of producing latex foam. While the latex is in liquid form it is foamed and poured into a mold. The mold is then closed up and placed on a conveyor belt. The mold is then moved on the conveyor belt into a vulcanization oven.
After vulcanization is complete, the latex foam can be removed from the mold and placed into a washing station. The foam is thoroughly washed to remove any soaps and excess material from the foam. Thorough washing of the foam allows the foam to retain its elasticity, counters aging and ensures it’s purity. After washing, the foam is fried at a high temperature to remove all moisture from the final product.