How It's Made

Patented Natural Memory Foam

Perfecting the world’s only natural memory foam took love, science, testing and time. What Essentia achieved in doing was to take high quality natural and organic ingredients, turning them into a truly next generation, latex-based foam that sleeps cool, feels better, and reacts faster than any other foam you’ve ever experienced. Essentia’s patented natural memory foam starts with Hevea milk that is mixed with other essential natural and organic ingredients that once combined help to achieve the distinctive feel and properties found only in Essentia. Of utmost importance to Essentia was sourcing the right ingredients to make our organic mattresses and natural memory foam mattresses, but also being transparent with what ingredients are used. Here you will find a breakdown of the most used ingredients in our mattresses:

Hevea Milk

Milky white "sap" of the Rubber tree, collected much like Maple tree sap. The hevea milk used at Essentia is sourced from Indonesia, collected from rubber plantations where acceptable working conditions are maintained and there is no practice of child labor. This hevea milk is processed to make our natural memory foam.

GOLS Certified Organic Latex

Essentia’s Lifestyle organic mattress collection features GOLS (Global Organic Latex Standard) certified organic latex.

Dunlop Latex

A rubbery foam made from Hevea Milk (rubber tree sap) which is known for its durability, support qualities, and purity. We use natural Dunlop latex foam, the finest natural latex foam available as the support core in many of our mattress models. 

Organic Essential Oils

A natural and healthy alternative to man-made oils or petroleum. Grapefruit seed, coneflower essence and jasmine essence all help us achieve proper consistency in our natural memory foam while providing soothing and rejuvenating properties to the body and spirit.

Natural Plant Extracts

As a substitution to harsh toxic chemicals used in conventional memory foam, plant extracts such as hydrolyzed corn help us achieve the proper consistency for our natural memory foam.

GOTS Certified Organic Cotton

Every Essentia mattress is covered in an organic cotton cover and we feature only the best organic cotton sheets. Grown without chemicals, synthetic fertilizers or pesticides, organic cotton helps retain the health of our planet and its people by providing safe work environments for cotton field workers, eliminating the use of damaging synthetic pesticides ensuring soil fertility is maintained and improved. 25% of the world's chemical pesticides are used to grow cotton when only 3% of the world's farmland grows cotton. Choosing organic cotton makes a huge difference.

How We Make the Best Organic Mattress

Perfecting Essentia’s natural memory foam was just the beginning, the next step was taking it to production. To ensure a consistent product, a very specialized foaming machine was sourced. After months of re-engineering and modifications including adding a programmable control center, chiller system, robotic arm and injection mix head she was ready to start making mattresses.

Essentia uses two different types of molds to make their organic mattresses:

Layer Mold
Used to make a thick piece of our natural memory foam. Once baked and cured, it’s sliced into 1 inch, 2 inch, and 3-inch thick layers to be used on mattresses. You’ll find these layers in all models but featured predominantly as comfort natural memory foam layer of our Classic 8 and Energie Opus models.

Essentia Patented Mold Technology
The specialized foaming machine is mostly found working with the mold to create our WholeBodyTM Recovery mattresses. The process is simple, a layer of natural Dunlop latex and natural memory foam that was sliced from the layer mold are stacked into this mold. The arm of the foaming machine then pours Essentia’s high-density natural memory foam over the stack, covering the top and all sides… much like icing a cake. The mold is then fully baked and the new mattress is ready to go into curing.

As 1 of only 2 latex foaming companies in North America, we not only have complete control over every ingredient and component used to make the healthiest mattress possible, the environmental benefits of foaming are significant. Instead of importing latex foam components, we simply import the rubber tree sap to make our natural memory foam. This takes close to 80% less space than importing finished latex foam. It also significantly cuts down on fuel consumption in transportation, which allows for better prices and supports the North American economy.

Best of all, all Essentia products are manufactured and distributed from Essentia’s GOLS and GOTS certified organic factory just outside of Montreal, Quebec.

Curing & Testing

As much care is taken into crafting a new Essentia mattress as you would expect from any James Beard Award-winning baker. Essentia’s goal is to ensure that each mattress reflects what Essentia owners are meant to feel which is fully refreshed after a deep, restorative, truly therapeutic sleep experience on Essentia. To ensure that, there are 2 more steps before a new mattress begins its trek to you:

Phase 1 - Curing Like all baked goods, Essentia 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 products cure on racks 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 Essentia 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 are needed for our team in the factory given the nature of our natural products. VOC testing has been performed on both work environment in our factory and the final product. Essentia’s factory is both GOTS (Global Organic Textile Standard) and GOLS (Global Organic Latex Standard) certified.

We also put a lot of stock into the environment and our impact on it, which is why it was extremely important for us to find the best solution to ship Essentia mattresses. It takes special machinery to compress, roll and pack mattresses as dense and heavy as Essentia, something that hadn’t been done on a product this dense. Upgrading compressors, motors and a gentle re-tool of a custom Italian-made Roll-Pack Machine made it possible. Almost all Essentia products are delivered via UPS or FedEx. The ones that aren't, are simply too heavy for standard delivery methods. What does roll packing mean for the environment? It means they take 75% less space in a truck and 75% less packaging. Our boxes are made from 100% recycled paper (99% post-consumer, 1% post-industrial). The bottom line is, you can be sure that you’re purchasing a world class, safe, and healthy product.

The Test of Time

Once you have made the decision to jump on an Essentia mattress, you have the added guarantee that it will stand the test of time. Essentia’s mattresses feature a 20-year warranty! To demonstrate the durability of Essentia’s high-quality mattresses, to the right you will find a chart indicating the height change of an Essentia mattress over a 10-year period. To conduct the test, a 250lb hexagonal shape roller passes over the mattress 200,000 times, which simulates 10 years of use. What was found is that the Essentia mattress experienced a loss of less than a quarter inch of its original height at the 10-year mark. Based on these results, it’s safe to say you can expect your Essentia to stand the test time, with the added security of Essentia’s twenty-year warranty.

Fun Fact: if you were to leave an Essentia mattress fully exposed to the elements (wind, rain, sun) it will biodegrade in just 3 years.

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