Long staple cotton has a growth period of approximately 150 days. Every year, cotton is sown in March and harvested by hand in September in China. Raw harvested cotton is then sent to the processing facilities in densely packed bales.
Once the cotton bales arrive at the factory, they are subjected to a series of procedures and drastic transformation before they can be used in the final product. Raw cotton contains fibre that also comes with other plant parts and extraneous impurities. Hence, the cotton bales have to undergo tenuous steps of opening, cleaning, scouring and purifying to remove the impurities.
The following step involves packing the cotton into large rolls (imagine a Bundt cake) for carding, and each cotton roll must not exceed 22kg. The white cotton rolls are transported into the carding machine, where they are combed into smaller pieces of soft cotton, just like snowflakes. This is a patented technology by our supplier where nearly a thousand layers of cotton yarn are repeatedly interwoven and laid to achieve an internal structure that is light and soft yet extremely elastic. This technology impedes issues that happen to traditional quilts, such as rigidness, delamination, separation and agglomeration.
Once removed from the carding machine, the cotton quilt is put through a compressing process to improve its durability. Each quilting is also measured, weighed, trimmed and sewn by hand to ensure each blanket is finished at the highest standard before it finally arrives at your home. Unlike many manufacturers, we take pride in our handcrafted products that touch people’s hearts and bring warmth to their homes.