The Baavet story began on our farm in Snowdonia, and that really is where your Baavet still starts its journey. These days we have been joined by many more sheep farmers from the rugged hills of North Wales and Snowdonia. All of our farmers are renowned for producing excellent quality wool, for which we pay them a premium price. We buy our wool directly from the farmers, unlike other wool duvet companies, because we believe, as primary suppliers, they should receive a fair price.
Shearing time on the farms is from late spring until early summer and this usually involves the whole family, with jobs for everyone.
The wool is taken from the farms to our wool merchant’s warehouse in Halifax where the wool is graded, because we can’t use all of the wool for your special Baavets. This is a very skilled job which takes years of practice.
Once the wool has been graded it’s taken to Dewsbury, to one of only two professional scourers left in the country; scouring is the term used for washing the wool.
The washing process removes the lanolin, the natural oil, and any dirt or animal muck. Our wool has a second washing process to make it even cleaner. No chemicals are used other than a standard washing detergent, similar to the ones used domestically. The lanolin extracted during the scouring process is used in many different industries, including pharmaceutical and cosmetics. Even the sheep muck and vegetation that’s washed out returns to farms as manure. The washed wool is dried and then baled into approximately 300 kilogram bales ready to be shipped to our factory in Porthmadog.
So it’s just a short round trip, from the farms of North Wales to Yorkshire and back again, where the manufacturing process starts in our small factory with our modern all purpose production line in Porthmadog.
The wool in the bales is tightly compressed so it’s placed into a large hopper where it’s agitated to break it up before it is fed into the giant carding machine. These machines consist of a series of large rollers that have hundreds of tiny spikes all around them which pull, or tease, the wool out into longer fibres.
After travelling around the rollers the teased fibres are then fed onto a continuous moving bed of soft fluffy fibre. This then continues through a cross lapper that produces different thicknesses and weights depending on the wool’s eventual use.
From the cross lapper this fine fluffy wool is then is fed directly between 2 rolls of the finest cotton fabric.
The carded wool then goes into the multi-needled quilting machine. The wool is now firmly enclosed in the cotton fabric so it won’t ever move around. The quilt then passes through and onto a cutting table where its into usable sizes.
This professional production line means that once the wool enters the system we don’t have to handle it so it ends as a light, fluffy fibre just like it is on the sheep. This means the wool can be full of air creating a fully breathable fibre ideal for sleeping under.
From the cutting table the sized quilt is transferred to our talented sewing machinists who put the final touches to your Baavets. First the binding has to be sewn all the way around then its passed to a second sewing station to have the binding ends reinforced and our iconic embroidered logo is sewn on before being packed and shipped. From you to ewe!
We are manufacturers of wool duvets, pillows, mattress protectors and natural fibre mattresses. Made in the UK with 100% British wool.