How Does Wool Perform at a Factory Level? Are There Any Limitations?
Wool is becoming an increasingly popular choice in manufacturing due to its natural strength, sustainability and versatility. But how does it perform at a factory level during manufacturing? Here’s a detailed look at how wool holds up in production processes, its efficiencies, and any limitations to keep in mind.
Key Takeaways
Factory-Ready Performance: Wool integrates seamlessly into existing workflows, cutting and glueing as efficiently as synthetic materials.
Enhanced Efficiency: Wider rolls and natural stretch improve material yield and reduce waste during production.
Compatible with Machinery: Wisewool™ Cloud works effortlessly with traditional blowing machines, requiring no significant equipment changes.
Sustainability Advantage: Wool provides a renewable, eco-friendly option for manufacturers without compromising on quality.
Manageable Limitations: Regular tool maintenance is the only minor adjustment needed to accommodate wool’s robust fibres.
“Wool has up to 15% more stretch than synthetic materials while holding its form, making it easier to work with in upholstery and layering processes. This added stretch reduces material waste and enhances overall production efficiency.”
Wool’s Strength and Versatility in Manufacturing
Wool is a naturally strong fibre, making it highly durable and well-suited to industrial processes. Unlike synthetic materials, which can break down under stress, wool maintains its integrity during cutting, glueing, and stretching. Here are the key benefits of using wool at a factory level:
| Fiber Type | Tensile Strength (MPa) | Eco-Friendly | Elasticity and Durability |
|---|---|---|---|
| New Zealand Wisewool | 150-200 | Yes | High loft and elasticity; excellent resilience |
| Wool (General) | 100-170 | Maybe. It depends on the processing technique use | High loft and elasticity; excellent resilience |
| Cotton | 100-120 | Yes | Low loft and elasticity; wrinkles easy |
| Silk | 300-500 | Yes | Moderate elasticity; retains shape |
| Polyester | 250-300 | No | High elasticity; wrinkle resistant |
| Nylon | 600-800 | No | Very high elasticity; excellent recovery |
1. Cuts and Glues Like Synthetics
Wool can be cut and glued like synthetic materials, ensuring it integrates seamlessly into existing manufacturing workflows. This makes transitioning to wool simple for factories already set up for synthetics.
What glue may be used with Wisewool - Wool may be adhered with any glue - synthetic or natural, so no changes need to be made at the factory level…only the natural change to fit wool's natural attributes seems commonplace.
What cuts wool - a simple pair of sharp scissors, electric-powered fabric cutters, and rotary cutters, especially with tungsten blades works well with the Low Loft High Density blanketing. High Loft, Low-Density blanketing prefers scissors. Industrial guillotine cutters are used for cutting multiple layers, and a band saw with blades designed for textiles such as wool can cut through various layers.
2. Better Structure and Efficiency
Wool rolls, such as those used in upholstery and other applications, offer:
Improved Structure:
“I’ve found Wool provides 15% more stretch compared to the traditional polyester wadding we use. Therefore it’s easier to work with in upholstery, more efficient and makes for a better layering process” - Stephen from SJK upholstery.Higher Efficiency: This added stretch reduces material waste and enhances production efficiency.
4. Wider Rolls for Better Yield
Wool rolls, usually supplied in 2.4m widths, offer significant advantages over narrower synthetic rolls:
Increased Yield: The wider working width allows for better material utilisation and less waste.
Fewer Joins: With wider rolls, factories can reduce seams and joins, saving time and improving product quality.
Off cuts can be used: they can be shredded or layered to create padding for sofas, chairs, and headboards, providing natural comfort, insulation, and breathability. Wool will also adhere to itself, making it easy to join pieces without seams showing.
5. Wisewool™ Cloud and Blowing Machines
Wisewool™ Cloud works exceptionally well with traditional blowing machines for feathers or synthetic fibres. Its natural fibres:
Separate and Fluff Easily: The blowing process helps loosen and fluff the fibres, making them ideal for applications like cushioning or padding.
Adapt to Existing Systems: Factories equipped with other materials can use Wisewool™ Cloud without significant equipment changes.
Fills evenly into cushions and pillows through a blowing machine as it captures air between the wool fibres which distributes wool perfectly into applications unlike feathers that have no compression resilience so just ‘pack down’.
6. Other Wisewool™ Manufacturing Benefits
Better work environment: Any wool you add to your work environment offers workers and consumers many health benefits:
Wool is resistant to dust mites, mould and mildew.
It contains lanoline that inhibits bacterial growth,
Wool regulates temperature and helps with moisture-wicking
Wool (if retaining its natural attributes through processing like Wisewool) can absorb harmful volatile organic compounds (VOCs) contributing to a healthier indoor environment.
Wool is a superb natural dehumidifier.
Wool has significant fire retardant properties.
Wool is anti-static so it does not easily collect dust
Limitations to Keep in Mind
While wool performs exceptionally well, there are minor considerations for factory use:
Tool Maintenance: Wool’s strong fibres mean cutting tools may dull faster, requiring regular sharpening or replacement.
Initial Familiarization: Factories that are used to synthetic-only materials may need a brief adjustment period to optimise processes for using wool but it is more in set up practices to accommodate the use of wool and making the change.
These limitations are easily outweighed by wool’s benefits, making it a practical and efficient choice for manufacturers.
Summary
Wool is a factory-friendly material that is easy to use in any manufacturing process with minimal limitations and significant advantages. Its strength, efficiency, and compatibility with existing workflows make it an excellent choice for manufacturers looking to incorporate sustainable, high-performing materials into their production processes.
Interested in how Wisewool™ can enhance your manufacturing?