How Does Wool Work In Quilting Machines for the Mattress Industry?
This article dives into how wool operates effectively with quilting machines, meeting the mattress industry's demands for quality and sustainability.
Key Takeaways
Clean Running: Use wool with low-vegetable matter content for operational efficiencies to reduce needle breakage
Consistency: Ensuring a consistent gsm of wool so that it carries well through the quilting machine.
Compatibility: Seamless Quilting Machine Compatibility so no added setup costs.
Eco-Friendly Luxury: Natural fibres create breathable, comfortable mattress layers while appealing to sustainability-conscious consumers.
Durable and Reliable: Wool fibres maintain their structure during quilting, for consistent performance compared to synthetics.
Customisable Options: Wool meets any level of loft for comfort requirements.
Enhanced Consumer Appeal: Wool's natural benefits, including temperature regulation, moisture wicking and hypoallergenic properties, deliver superior sleep experiences.
How are Quilting Machines Used in Mattress Construction?
Quilting machines are essential in mattress manufacturing, stitching fabric and filling layers into secure, consistent comfort surfaces. The machines create comfortable top and side layers of mattresses to remove hard edges by sewing precise patterns that hold the wool in place. These machines ensure durability, efficiency, and quality, making them indispensable in large-scale production.
When selecting wool for use in your quilting machine, consider the following points:
Consistent GSM: Ensure the fibre maintains a consistent GSM (grams per square metre) throughout the entire roll.
Low Vegetable Matter: Choose wool with no or very low vegetable matter to prevent it from sticking through the outer quilting layers or discolouring outer materials. Low vegetable matter also reduces wear and tear on quilting needles.
Correct Width: The wool should match the working width of your quilting machine, with some overhang to allow for easier handling.
Adequate Thickness: The material should be thick enough, ideally 200 GSM or more, to pass through the quilting machine without being pulled or overstretched.
How clean wool can impact quilting production?
Using pure wool when quilting is essential to prevent wear and tear on quilting machinery and needles. This is particularly important regarding the amount of vegetable matter (plant material such as seeds, burrs, and grass) present in the wool. You should ensure that the wool you source contains little to no vegetable matter to prevent machinery needles from breaking.
Top two benefits of wool in quilting machines
Quilting machines are traditionally optimised for synthetic fillers like polyester. However, with advancements in wool processing, wool now rivals synthetics in both ease of use and performance:
Ease of production: Wool carries and runs through quilting machines as easily as synthetic materials.
Strong Fibres: It's natural elasticity and robust fibre structure enables it to glide through quilting machines without compromising on manufacturing performance.
“The needles in our quilting machines overheat far less when using Wool instead of synthetics. We believe that it is much better for the longevity of our quilting machines”.
- Verdynan Sarlim - Mattress Manufacturer
Top Five Key Benefits of Wisewool™ in Mattress Production
1. Low Vegetable Matter Content
By sourcing directly from farms and selecting only premium-quality wool with 0 - 0.1% vegetable matter content, Wisewool™ prevents issues such as needle breakage and visible plant material on outer fabric layers. This results in smooth feeding into automated quilting machines, reducing machine downtime and improving the quality of finished quilting.
2. Structural Integrity
Wisewool™ needle punched blanketing offers superior hold together and uniformness of fibres due to the quality of wool sourced. This is only further enhanced by the decades of non-woven knowledge within the industry. This consistent product ensures less quilting is required to produce a consistent product. Wider quilting channels can be used as a result and allows more options in creating a quality product.
3. Sustainability Advantage
Strong wool is a renewable and eco-friendly resource. Wisewool™ supports ethical farming practices and minimal processing. Incorporating Wisewool™ helps mattress manufacturers meet the demands of eco-conscious consumers who prioritise sustainability in their purchasing decisions.
4. Full Traceability
Wisewool™ offers complete traceability back to the source farms, ensuring consistent quality control. With over 130 years of family experience in wool farming, Wisewool™ provides a trusted and transparent supply chain that reassures manufacturers and customers alike.
5. No Off-Gassing
Wisewool™ uses chemical-free wool cleaning methods and natural odour reduction, making it an ideal choice for those with chemical sensitivities. This results in a safer, healthier sleeping environment without harmful emissions or synthetic smells.
In Summary
Wisewool™ is transforming the mattress industry by making it easier than ever to integrate strong wool into quilting machines. Its durability, eco-friendly credentials, and luxurious feel provide a competitive edge for manufacturers.
Ready to integrate Wisewool™ into your manufacturing process?
