Wool blankets are cherished for their warmth, durability, and natural beauty. But have you ever wondered how these cosy blankets are crafted? In this blog, we will walk you through the fascinating process of wool blanket production, step by step.
Step 1: Sourcing the Wool
The journey of a wool blanket begins at shearing sheep, where the wool is carefully collected to ensure quality. This initial step is vital, as it sets the foundation for the entire process. Not all wool is created equal; the breed of sheep can greatly influence the texture and warmth of the wool.
All our blankets are crafted with wool from New Zealand, which is known for its exceptional quality and is ideal for creating blankets that are both luxurious and long-lasting. Its naturally soft, strong fibres provide comfort and resilience, ensuring our blankets maintain their shape and plush feel. The wool’s brightness allows for vibrant, lasting colours, while its hypoallergenic properties make it perfect for sensitive environments.
Once shearing is complete, the wool is sorted. This sorting process ensures that only the finest quality fibres make it to the next stage. After all, a comfortable and cosy wool blanket starts with the best raw materials.
Step 2: Cleaning and Preparing the Wool
Once sourced, the wool goes through a cleaning process to remove any debris, followed by carding to separate and align the fibres. Cleaning is essential, as it eliminates grease and contaminants that may have accumulated during shearing. This step ensures that the wool is hygienic and ready for processing.
After washing, the fleece is carded, which involves passing the wool through a series of rollers fitted with fine wires. This aligns the fibres, making them easier to spin into yarn, while also softening the wool. Proper preparation of wool fibres also contributes to the overall texture and feel of the finished blanket. Smooth, well-prepared fibres result in a more luxurious blanket that is pleasant to snuggle under.
Step 3: Spinning the Wool into Yarn
The cleaned and carded wool is then spun into yarn, which gives the blanket its strength and texture. This spinning process can vary depending on the desired thickness and texture of the yarn. A finer yarn will create a lighter blanket, while a thicker yarn can contribute to added warmth.
Spinners use various techniques, from traditional wheel spinning to modern machinery, ensuring that they produce yarn that is consistent and robust. The yarn must be strong enough to withstand the weaving process and the wear and tear of everyday use.
Different spinning techniques can also affect the elasticity and drape of the final product. This means that the choice of spinning method can influence not just the blanket’s appearance, but also its functionality.
Step 4: Dyeing the wool
Before weaving begins, the wool fibres are dyed to achieve rich, vibrant colours that will last. Using high-quality, eco-friendly dyes, the wool is carefully coloured in small batches to ensure consistency and depth. This process allows each fibre to fully absorb the colour, resulting in hues that are both striking and enduring. Dyeing at this stage ensures the colour remains vibrant and evenly distributed throughout the blanket, adding to its unique, artisanal character.
Step 5: Weaving the Blanket
After the yarn is spun, the next step involves weaving it into the blanket using various techniques to create unique patterns.
Weaving can be done using a variety of techniques, including plain weave, twill, or jacquard weaving. Each method contributes to the blanket's overall aesthetic and durability. Our blankets have been handcrafted with a plain weave.
The skill of the weaver also plays a significant role at this stage. Experienced weavers can manipulate the yarn expertly to create intricate designs and textures that elevate the blanket's appeal.
Step 5: Finishing Touches
To ensure the highest quality, each blanket is then thoroughly washed, shaped, and pressed to enhance its softness and durability. Finally, it undergoes a meticulous quality control inspection to catch any imperfections, so only the finest blankets make it to your home.
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