How It's Made


We make recycled wool blankets using offcuts from the factory floor – but how do we actually do that? 
Currently our recycled blankets are made at the same mill that the offcuts are produced. Other than our blankets, the mill spins and weaves fine blankets made from alpaca, mohair and wool for their customers. It's the by-product from this process we use to make our blankets. 
1. Collection: offcuts are collected from the factory floor 
As the other blankets are produced, the technicians collect the offcuts from the production process. This might be from the spinning or weaving stage, and can be from overruns, trimmings and scraps that aren't part of the final product. 
waste ready to be shredded
2. Shredding: offcuts get shredded
These offcuts are ripped up in an industrial ragging machine into many small fibres of consistent size and shape. 
shredded waste ready for cleaning and carding
3. Carding: shredded fibres are carded
Then, the carding machine cleans and makes all the fibres parallel in preparation for spinning into yarn.
waste
4. Spinning: carded fibres are spun 
Spinning is essentially twisting fibres together. Because a strong yarn needs long fibres bound together, a small amount of polyester is included so that the short recycled fibres have something to grab on to. 
Ricky loading up the spun yarn ready for weaving
5. Dyeing: introducing colour! 
To introduce colour, blankets are either dyed after they are woven, or beforehand as hanks of yarn from the spools. 
dyed yarn
6. Weaving: yarn is woven
The looms are operated by highly skilled weavers who know how to perfect the tension (so that the final blankets aren't "tighter" in some places than others) to create an even surface. 
loom with woven fabric
7. Milling: woven fabric is milled
This is a washing process to felt and tighten the weave of the fabric, where the blankets get whipped around big cylinders over and over again. Wool fibres have many tiny teeth that lock closer and closer together with warm water and friction. Milling also determines the width of the fabric as it shrinks. 
8. Finishing: final touches are applied
After the recycled blankets are milled and dried they are finished with whipstitching or fringing. Then the labels are applied and the blankets sent to our warehouse for distribution. 

But it doesn't end there! Our care instructions are provided to extend the life of your blanket. When you are finished with your blanket, you can return it to us free of charge and we can re-manufacture it: adding it to the ragger with the other offcuts to be spun into new yarn and woven into new blankets. That's what we mean by 'closed loop', where the same resources are cycled through the same process to offer a useful product with little to no waste, and of equal or higher value.