Carding is a precisely monitored operation using a series of progressively finer spiked roIlers to comb out the wool fibres into a fine, uniform web. Carried along an array of narrow conveyor belts, the layer of wool is divided into narrow strips, or 'slubbings'. It is these strips which are roIled into fragile strands before being loaded on to the spinning frame. The slubbings are then spun at more than 5000 rpm into a single ply yarn.

By twisting the strands together, as two or more ply, additional strength and density is acquired by the yarn, affecting the eventual weight and quality of the finished carpet. The yarn is wound into hanks, before a final washing to enhance the dyeing technique.

Colourfast dyes are used to produce delicate subtle shades and colours. The composition of the dye, its temperature and the immersion time of the hanks are
closely monitored. A computerised system ensures precise matching to the colour required. The hanks are rotated in a hydro-extraction unit to remove excess moisture, before passing through an electronically controlled steam drying process to ensure uniformity of moisture content.

Once dried, the hanks are allowed to cool and condition naturally before being wound onto more manageable 'cones' and packaged for despatch to our weaving looms at Axminster. Several thousand kilos of yarn make this journey every working day.

The carpet is brushed to remove any foreign matter, and squared for alignment and symmetry. After further steaming to burst open the lush woollen pile, a coating of vinyl is applied to the back of the carpet to assist tuft retention and ease cutting and fitting. Further brushing is followed by a second and final tip shearing operation to ensure a smooth, level finish.

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