Thomas Kay Woolen Mill
Raw wool was delivered to the Thomas Kay Woolen Mill's warehouse in large bales. It would undergo many different processes before becoming a blanket. SORTING After wool was delivered to the mill, it was sorted. Different fibers have different uses. SCOURING Is the cleaning of the wool to remove lanolin and dirt through the use of water PICKING Is the process of mechanically removing foreign particles and vegetable matter from the wool fibers by means of metal teeth on a roller. Picking machines were also used to tear up used woolen garments for reprocessing and for blending different grades and sorts of wool. DYEING this could be done in several stages of the wool processing. Dying means coloring the wool by means of chemical and vegetable dyes. CARDING The wire-covered carding rolls comb and untangle wool fibers. The web of wool formed is separated at the end of the process into distinct strips called roving that is ready to be spun. SPINNING The spinning mule twists the roving into yarn as it moves in one direction, and winds onto bobbins on the return. The spinning frame, a later invention, performs the same process in a more compact and efficient manner. DRESSING This process prepares the lengthwise, or warp, threads to be placed in the loom. The threads are wound from individual bobbins onto spools, and then onto the warping reel. From there, they are wound onto the warp beam, are threaded through eyes in the wire heddles, and then through the reed. Finally, the warp beam, the warp, the heddles in their harnesses, and the reed are all placed in the loom for weaving. WEAVING: Weaving is the crossing of warp threads running lengthwise in the loom and weft threads, or filling threads, inserted crosswise. The weft thread is added by a shuttle carrying a bobbin of yarn. Our weavers’ guild is located on the 4th floor of the mill building and is open to the public on Tuesdays, Thursdays and Fridays if you’d like to see weaving in action. PERCHING After weaving, the fabric is hung on a “perch” for inspection. Imperfections are marked, then the cloth is cut and dropped through a trap door. It is then weighed, measured, ticketed and passed on to the burlers and menders in the finishing room below. BURLING The burler finds and removes knots, bunches and loose ends, then marks any “runs” to which menders to add missing threads. MENDING Menders re-weave yarn into the fabric by hand wherever threads are missing. FULLING The fulling mills use hot water, soap and agitation to shrink fabric. This controlled shrinking “felts” wool fibers, drawing them up, and creating a denser, thicker fabric. WASHING After fulling, fabric is washed and rinsed of soap, oil and dirt. EXTRACTING Excess water is squeezed out of fabric by the spinning action of the extractor before the material goes to the dryers. DRYING In early years, the fabric was stretched to dry on tenterhooks on long racks in the tentering room on the 4th floor. In later years, a hot air machine dryer was used in a shed attached to the 1st floor. RAISING OR NAPPING A nap or pile on the surface of the fabric is raised using nappers with wire-covered rollers. When these nappers replaced the old teasel gigs, many woolen mill hands predicted the metal teeth would destroy the wool, but that did not happen. SHEARING The pile or nap on fabric is trimmed by the lawn mower-like shear. The amount of nap removed depends on the type of finish desired. PRESSING AND FINAL INSPECTION The steam press smooths the fabric and gives it a finished look. The inspector looks for any imperfections or damage; damaged goods are often discounted to the purchaser, and imperfections could affect the weaver’s pay. PACKAGING AND SHIPPING Blankets are bound and yardage is folded, rolled, weighed and labeled. Orders are readied for shipping.