Recycling Process

How does the recycling process work? Waverley Mills Est. 1874 has made it’s recycled woollen blankets & throws using offcuts from the factory floor for decades. Today with research, innovation and creativity we continue to make recycled products, learn more about the process.


Step 1: Collection

Soft waste - anything pre yarn stage including raw wool waste, bobbin waste and table waste and hard waste – anything from yarn to offcuts, scraps, trimmings, product overruns and factory seconds are collected by our technicians from the Waverley Mills factory floor.


Step 2: Shredding

These offcuts are ripped up in an industrial ragging machine (also known as garnetting) to create many small fibres that are a consistent size and shape. During this process the fibre comes out in a smaller length.


Step 3: Carding

The carding machine mixes and makes a continuous web of all the now parallel fibres in preparation for spinning into yarn. At this stage is when we mix the recycled wool and other fibres to make our recycled blend. It’s also at this stage where our skilled technicians are able to adjust the mix in real time so we have a soft but strong continuous web for spinning.


Step 4: Spinning

Spinning is essentially twisting fibres together. To make a strong yarn it is essential long fibres are used to bindbound the recycled fibre which has been shredded. The longer fibres are a recycled polyester which is under 15% of the total recycled mix.


Step 5: Dying

For colourful design elements, blankets are either dyed after they are woven, or beforehand when they are still hanks of yarn.

Step 6: Weaving

The Waverley Mills™ looms are operated by highly skilled weavers who know how to perfect the tension to create an even fabric surface.

Step 7: Milling

This is a washing process to felt and tighten the weave of the fabric, where the blankets get wound around big cylinders over and over again. Wool fibres have many tiny scales that lock closer and closer together with warm water and friction. Milling also determines the width of the fabric as it shrinks.

Step 8: Raising

Once the blankets have been through the wet processing (milling) stage they are dried and raised. The raising machine brushes the fabric raising the pile and giving a softer handle.

Step 9: Finishing

The final stage of the creation of the recycled blankets is cutting into individual pieces and whip-stitching or fringing. Then the labels are applied and they are ready for our #EcoFriendlyShipping