When our shepherds send us the wool, it arrives already washed of dust and the natural grease. The Wool arrives at Burel Factory in very dense and compact 200kg bales.
This wool, although washed, may contain one or another straw that may escape through the entire process of transformation, and may even be in a Manteca blanket that you take home.
The bales enter a machine called a Loba Abridora or Loba Misturadora that opens the fibers and mixes the colours while it softens it. After this it will rest a few hours in the chambers and then begin to be carded.
We worked with three cardas on Belgian machines over 100 years old that started to steam, passed the naphtha and only later were adapted to the electricity.
The cards will merge the fibers to achieve uniformity in colour and texture. They tame and orient the fibers in the same direction and form the veil that forms in small strips, open the fibers in order to create a stir. The stir is not yarn as it does not yet have the necessary strength.
The stirring rolls are placed in the spinning and drawing yarn to form the yarn in the desired thickness depending on the final purpose and the type of fabric desired, whether is burel fabric, blankets, flannel or other fabrics.
We pass the straws out of cardboard spinning, to reels (on the rewinder) and some of these reels are passed to shins (in the shin box).
It’s time to start weaving.
We supply the looms with the reels and the shins so we can turn them into books. The cloth when it leaves the loom is heavy and measured. It goes to quality control, where light or artificial haulers or yokes, sweep the fabric with the eyes in order to cut the knots and one or another yarn that may have been of a different thickness, then the ladies, seated with a needle and a thread, remove this piece of different thread and place another of the same thickness.
After that, there is the process of finishing, the so-called miracle of the textile industry, which will transform the fabric into the final fabric with the softness, colour and roughness that we see in fabrics for clothing, decoration, stoving and architecture.
The fabric is beaten at the pumping while being moistened, which causes the fabric to shrink about 30% to 40%, felting and gaining the desired thickness.
Finishing are several processes that will stabilize the fabric and vary depending on what we intend at the end.
It is only after this long and meticulous process that we have the burel that he knows.