The steps of making a pure wool duvet

The steps of making a pure wool duvet

Manufacturing - 04/07/2017

The manufacturing of a pure wool quilt is done in several stages that involve several machines and know-how. We open the doors of our workshop to show the realization of these steps by our production team in Belgrade.

1 – Stacking of the fabric in successive layers

The first step is to cut the fabric in successive layers on the cutting bench. Everything is based on a cutting plan based on a production sheet and the width of the fabric. Our manufacturing is artisanal and this operation is done by hand. On larger productions it exists automated cutting benches.

Preparation of the cutting bench for the realization of the cutting plan.
Preparation of the cutting bench for the realization of the cutting plan.
Cutting the fabric in successive layers.
Cutting the fabric in successive layers.

2 – Marking and cutting of the parts

Once the fabric is stacked in the right number of layers, the cutting plan is drawn to delimit the different pieces. If the quilts produced do not occupy the full width of the fabric, the rest of the fabric is used for other products such as pillows or piping.

Marking the different pieces of the cutting plan on the fabric.
Marking the different pieces of the cutting plan on the fabric.
Cut pieces marked on all layers at once.
Cut pieces marked on all layers at once.
Fabric pieces for quilts ready to be used.
Fabric pieces for quilts ready to be used.

3 – Setting up wool for a duvet

The making of a duvet starts by putting the under layer fabric on the table. Then, the woolen layer is placed on the fabric and cut to the correct size. One wool layer is about 200g/m2. Depending on the type of duvet produced (Ninaja 200g/m2, Hajla 400g/m2 or Maja 600g/m2), 1, 2 or 3 layers of wool are used. In this production, it is Hajla with 2 layers of wool that was produced.

Placing the first layer of wool on the fabric.
Placing the first layer of wool on the fabric.
Cutting the excess wool. This wool is reused in other products such as cushions or returned to the supplier for reuse.
Cutting the excess wool. This wool is reused in other products such as cushions or returned to the supplier for reuse.
Placing the second layer of wool to make Hajla 400g/m<sup>2</sup>.
Placing the second layer of wool to make Hajla 400g/m2.

4 – Putting the quilt on the quilting frame

Once the quilt is assembled, small cloth pegs are placed on its periphery to hold the fabric and the wool. It is then placed on a quilting frame. We have fabricated our quilting frames ourselves to be exactly adapted to our manufacturing. They are made of wood, with metal needles on which the quilt is stitched to hold it.

We have several quilting frames depending on the size of quilt to make. The same frame is adaptable for several sizes.
We have several quilting frames depending on the size of quilt to make. The same frame is adaptable for several sizes.
Placing the duvet on the frame.
Placing the duvet on the frame.
The quilt is stitched on each needle of the frame to maintain it. This requires some experience not to prick oneself.
The quilt is stitched on each needle of the frame to maintain it. This requires some experience not to prick oneself.

5 – Quilting the duvet

The frame is placed on the machine that performs the quilting. There are basically 2 techniques for quilting: continuous and using a frame. The continuous industrial quilting is not adapted at all to the delicacy of woolen layers. The handmade quilting on frame is the one that gives the best result.

The quilting machine is computer controlled. We have realized our programs ourselves so that they are completely original and perfectly suited to our needs.

Quilting of the duvet.
Quilting of the duvet.
Detail of the duvet quilting seam.
Detail of the duvet quilting seam.

6 – Cutting the duvet to dimensions

Once the quilting is completed, the duvet is taken out of the frame to go to contours cutting. This step ensures the right dimensions, having straight edges and removing the part of the fabric stitched by the needles of the frame.

Cutting out the contours of the quilt.
Cutting out the contours of the quilt.

We have built a specific cutting ban that guarantees a fast, safe, straight cut.

The cutting ban allows a straight and fast cut.
The cutting ban allows a straight and fast cut.

The last part of the cutting for the duvets is the rounding of the corners. This facilitates the sewing of the piping and gives a nice aesthetic to the product.

Rounding the corners.
Rounding the corners.

7 – Laying labels and piping

With the duvet cuts to the right size, the last stage of manufacturing is to sew labels and piping all around. It is an essential step which ensures the wool will stays in place all around the quilt. We use a powerful triple drive machine for this job.

Sewing the piping around the quilt.
Sewing the piping around the quilt.
The labels are sewn before starting to sew the piping. The piping then passes over.
The labels are sewn before starting to sew the piping. The piping then passes over.
2 piles of duvets, one of quilts ready to be packed, the other of quilts waiting for finishing.
2 piles of duvets, one of quilts ready to be packed, the other of quilts waiting for finishing.

8 – Packaging of the finished product

The duvets are finally folded manually and packaged in a bag adapted to their size.

Movie of the production