We carefully craft the yarn
The yarn is meticulously loaded onto a warping creel and twisted around the drum under tension for the required length and warp-threads. This process can count anywhere between 1800 and 5500 threads. Once this lengthy procedure has been completed, the warp is carefully transferred onto a beam.
Each individual warp-thread is then drawn through a heddle which sits on a series of shafts. This is done in a particular order specified by the required weave structure. Next, each thread is pulled through a comb-like structure called a reed.
A DELICATE AND METICULOUS PROCEDURE
Each individual warp-thread is tied to an existing warp end in the loom in alternation. This tying method eliminates the need to draw the warp.
However, in order to achieve this, any new warp must have exactly the same number of ends, identical reed and draft as the existing warp.
ONLY THE BEST GETS THROUGH
The beam with the shafts and reed is now ready to be placed in the loom and set for the specific task. Weft yarns are loaded onto the machine with the required weave structure programmed into a state-of-the-art device.
During this part of the cloth creation, the weft yarn travels across the warp. The shafts lift in a specific order to create the required weave structure, such as a plain weave pattern, prunella, and twill.
FINISHED TO PERFECTION
Once woven, the cloth is then thoroughly checked on both sides for any flaws. Even the most minute of imperfections are carefully rectified, with any knots pulled to the back of the fabric.
The cloth will then undergo one of many different completion stages and final checks, dependent on the finish of the material. The four main finishing stages are scouring, milling, cropping and pressing.
Finally, the cloth is rechecked for any further blemishes, before being given the 'seal of approval', as an heirloom of the future.