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!



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.

2: Clean and Shred

Next, the plastic bottles undergo a thorough cleaning and sterilisation process to remove any contamination. This cleaning stage is to ensure all recycled plastic achieves a very high level of purity.

After cleaning, the bottles are subjected to shredding, where they are transformed into small chips or flakes. This shredding process serves multiple purposes. Firstly, it increases the surface area of the plastic, making it more accessible for subsequent processing steps, while it also ensures consistent quality and properties throughout the recycled batch.

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.

4: Fiber to Fluff

Next the microfiber is processed through a specialised machine that ‘crimps and cuts’ the fiber. This introduces waves or bends into the fiber which adds volume and resilience to the fibers, ensuring they can provide adequate loft and support when used as fill.

After crimping, the fibers are cut into shorter lengths, typically ranging from 2 to 6 centimeters, depending on the desired characteristics of the final product. The cutting process ensures that the fibers are of uniform length, enabling consistent quality and feel within the end product. These are then baled and prepped for carding.

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.

6: Combining to Quilting

After carding, the web/mat is trimmed to the correct size and weight.

The amount of fiber used determines the loft and firmness. The web/mat is evenly distributed between the quilt top and bottom fabric layers and goes through quilting machine creating a patterned or quilted effect. This process adds strength, stability, and aesthetic appeal to the final product.

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.

8: QC and Packaging

The finished luxury pillows undergo rigorous quality control (QC) checks to ensure they meet our standard in terms of appearance, comfort, and durability. During this phase we will inspect areas such as stitching and seam quality, size, the distribution of filling, and much more.

Once approved, the product is compressed using a vacuum sealing machine, resulting in a compact and space-saving package. Vacuum sealing also protects the item from dust, moisture, and insects during transportation and storage. When the package is opened, the item will regain its original shape.

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