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The 8 Steps To Turn A Bottle Into Bedding.
There are a few little secrets we haven’t included but this is a comprehensive overview!
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1: Source and Sort
Plastic bottles are sourced from a variety of places, including recycling centers, waste management facilities, and municipal recycling programs. Once gathered, these bottles undergo a comprehensive sorting procedure to eliminate contaminants and non-recyclable items.
During the sorting process, each item is carefully examined by trained personnel and/or automated systems to ensure its suitability for recycling. Non-recyclable items (i.e. bottle caps) are separated from the bottles and following processes.
3: Chips to Thread
The next step involves using controlled temperatures to melt down the small flakes into a molten plastic which is then passed through a extrusion tool called a spinneret. The plastic is forced through the spinneret under pressure which shapes the molten plastic into long, continuous strands which are known as filaments.
Following this is a process called Drawing. This involves stretching the filaments to improve the thread’s strength and give it a finer diameter. This results in a fine fibre, commonly known as microfiber.
5: Carding
In this step, the crimped fibers are loosened and separated through machines called openers or scutchers. The opened fibers are then fed into a carding machine where the fibers are aligned in a parallel arrangement while any remaining tangles or irregularities are removed.
The aligned and carded fibers are now processed to form a thin and continuous web or mat. This web is gradually built up as the fibers are transferred from one carding roller to the next. Once the web is formed, it is compressed and consolidated to increase its thickness.
7: Binding & Finishing
Once the quilting is complete, binding is added to the edges of the quilt. Binding is a fabric strip that is folded in half and sewn along the raw edges of the quilt to enclose the edges and provide a finished look.
Labeling adds the finishing touches: Quilts have varying labels attached to identify the brand, size, care instructions etc. Additionally, some custom product may receive additional finishing touches such as embroidery work.
