The wool is harvested and prepared annually by a shearing team, the shearers carefully remove the wool from the sheep.
The next process is scouring, wool scouring is removing most of the impurities from the wool, most of the wool grease, all mineral impurities and a small percentage of vegetable matter.
The bales of wool are transported to our factory placed in a bale breaker for opening of the wool for presentation for carding. Only nué wool is the manufacture of our Woolstar woolen products. The wool is then blown across into a large storage hopper ready for our carding process. The wool is transported from the hopper via an up belt, the carding process commences, this machine is state of the art and computer controlled.
The carding process is the combing and straightening of the wool fibres, this is achieved by a large number of small and large metallic rollers, the vegetable matter is also removed during the process.
A thin sheet of wool fibre is produced weighing from 100grams per sq metre to 1000grams per sq metre depending upon specification.
The crosslapper is a machine going back and forward laying on layer of carded wool, the computerized lattice removes the layer from under the crosslapper producing a continuous feed of wool with a constant density, the lattice continues to transport the wool to the multi-needle quilting machine, where it enters between two cotton fabrics.
Quilting & Cutting
The wool quilter product then proceeds to the panel cutter where the cut size is programmed into the machine, its quality check is made after the cut, to ensure the correct size, weight any fabric blemishes on missing stitches.
The quilt is floated to the machinist for binding using a high speed binding machine, the care label is placed on the quilt during this process.
Once the quilt is sewn the packer turns the quilt checks for binding errors, packs the quilt and the product is now ready for sale.