Blending
Blending is the crucial step between the Dye House and Carding: the moment when fibres are combined to match the precise shade card. During this process, fibres pass through opening machines that separate the staples and remove any remaining dirt and debris. A fine mist of lubricant is added via an atomiser to help the fibres move freely without damage.
Often referred to as the muckiest stage, blending is also one of the most time-intensive. It can take up to eight hours to blend a single 500-kilo batch.
Allowing the fibres swirl and mix thoroughly.
Before reaching the fearsome fearnought picker machine, the fibre first enters a vast mixing chamber: a large room where the fibres swirl and mix thoroughly.
A terrifying, but beautiful piece of machinery.
Once sufficiently loosened, the fibres are pneumatically transferred to the fearnought for a final opening and blend. As imposing as it looks, the fearnought is an extraordinary machine: powerful, precise and surprisingly elegant in motion.
Testing before bulk production.
To ensure the recipe is correct, some test blends are run through the sampling carding machine. This allows us to check that the resulting colour accurately matches the intended shade card before moving into full production.
