Where & How It’s Made
It took years to perfect the only natural memory foam in the world.
We mix Hevea milk, the milky white sap of the rubber tree, with essential oils like grapefruit seed, cone flower essence and jasmine essence. Plant extracts and water are added to help achieve the feel we’re known for.
The result is a next generation, latex-based foam that sleeps cool and feels absolutely amazing. We know how to get good sleep.
Building & Baking: How Our Mattresses Are Made
Perfecting our natural memory foam was just the beginning. The next step was making sure we could consistently recreate it on a daily basis.
To ensure a consistent product, a very specialized 18 year old foaming machine we call Bertha was sourced. We souped-up and re-engineered it for months, adding a programmable control center, chiller system, robotic arm and injection mix head among other modifications.
We use 2 different types of molds to make our mattresses. The first is our Layer mold, used to make a thick piece of our natural memory foam. Once baked and ready, we slice it into 1 inch, 2 inch and 3 inch thick layers to be used on our mattresses. You’ll find these layers in all models, but featured predominantly on our Classic 8 and Energie Opus.
Most of the time you’ll see Bertha working with the second mold format pictured here, used to make our WholeBodyTM recovery mattresses. We place a layer of natural latex (Dunlop process) and natural memory foam in the mold, then Bertha pours in our high density natural memory foam covering the top and sides like icing on a cake. Once the mold is fully baked, this new mattress is ready for the curing and testing phases.
Best part, this all happens in our facility just outside of Montreal in Quebec, Canada.
Curing & Testing
We’ve mentioned baking above and that’s because making an Essentia mattress really is like baking a cake.
As much care is taken into making a new Essentia mattress as you would expect from any master baker. Think of it this way, we need to make sure each mattress reflects what Essentia owners are meant to feel which is a full body experience.
Once made, there are 2 more steps before your mattress is on its way to you.
Phase 1 - Curing
Like all baked goods, our products need some time to cool. When it comes to foam, the cell structure and consistency changes after a few hours, even after a few days. All of our products cure on racks, just like bread, for 7 days to ensure you always get the Essentia feel we’re famous for.
Phase 2 - Testing
All Essentia mattresses undergo inspection and testing before being packed up and shipped to you. Including ILD (indentation load deflection) testing which determines firmness, stiffness or load bearing capacity.
Made with Care
When it comes to how our memory foam mattresses are made we’re not just a company, we’re family. Health, safety and happiness go hand in hand at Essentia.
Everything gets tested, from worker safety to the final product. No gloves or other forms of protective equipment is needed for our team in the factory given the nature of our natural products. VOC testing has been performed on their work environment and our mattresses.
Our factory is both GOTS (Global Organic Textile Standard) and GOLS (Global organic Latex Standard) certified.
You can be sure that you’re purchasing a world class, healthy product. We list all of our testing results on our Test & Certifications page.
So now you’ve decided you’d like an Essentia but you’re asking yourself: How long will it really last? Fear not, our 20 year warranty is all real.
Below is a chart showing the height change of an Essentia mattress over a 10 year period.
To test, a long 250lb hexagonal shape roller rolls over the mattress 200,000 times, which simulates 10 years of use. What was found is that the Essentia mattress lost less than ¼” of its height at the 10 year mark.
Based on these results, it’s safe to say you can expect your Essentia to last a VERY long time. And hey, if something were to happen, we have a warranty for that!