Here’s how Zenhaven brings you the world’s most natural sleep.learn more
Eco-responsibility is at the heart of everything we do at The Saatva Company. We insist that both the materials and the manufacturing of our beds be as healthy for our planet as they are for our customers.
All the Zenhaven principal materials are directly from nature: natural latex, wool, and organic cotton. The Talalay manufacturing process is entirely water based, and produces no environmentally harmful byproducts. And by producing both our latex cores and our mattress in America, we’re able to keep our carbon footprint smaller than manufacturers who import theirs.
It starts in the trees and ends in the healthiest, most glorious sleep imaginable.
STEP 1: HARVEST
Natural latex is tapped from tropical rubber trees, strained for impurities, and shipped to the Talalay production facility in America.
STEP 2: MIX
The liquid latex is mixed with a small amount of nontoxic, inorganic ingredients (needed for all latex production).
STEP 3: BATTER
The mixture is whipped into an airy batter.
STEP 4: MOLD
It's then poured into a mold studded with hundreds of narrow pins. These pins create cells that enhance latex’s natural breathability. (They’re also the secret behind Zenhaven’s unique 5-zone support structure.)
STEP 5: CREATE A VACUUM
A vacuum is created, drawing the latex into every corner of the mold. (This step is unique to the Talalay process. By varying the amount of latex used, the firmness of the final product can be customized. To vary firmness in the Dunlop process requires the addition of chemical fillers.)
STEP 6: FLASH FREEZE
The temperature is quickly dropped to -20° F, freezing the latex particles in place and ensuring a consistent cell structure. (Again, this step is unique to Talalay — the reason our latex has a much more supple and consistent feel than Dunlop latex.)
STEP 7: SET
The pH is neutralized and the latex material begins to set.
STEP 8: CURE
The latex is heated to 230° F to “vulcanize” it, essentially baking it into solid form.
STEP 9: WASH AND DRY
The mattress core is removed from the mold and washed five times in pure water, rinsing away any potential impurities or allergens. It’s then gently and thoroughly dried for three hours.
STEP 10: TEST — AND TEST AGAIN
Each mattress core is then tested for consistent firmness in nine places. A separate inspection uses infrared to look for internal flaws.
STEP 11: ASSEMBLE
Approved mattress cores are shipped to one of our 18 partner factories. Final assembly involves combining several layers of Talalay latex — firmer at the bottom, more resilient at the top — and a layer of wool. It is then wrapped in a lush organic cotton cover.
STEP 12: DELIVER
We deliver and set up Zenhaven in your bedroom.