Materials for the production of blankets and pillows. Profitable business: production of pillows and blankets

Bulky pillows and thick woolen blankets are gradually losing their popularity. Traditional natural materials, which have certain disadvantages, have given way to more modern raw materials, as well as cheap synthetic fillers that have big amount benefits. As a result, the process of making bedding was greatly simplified and automated, which made it possible to reduce the costs of organizing our own production.

The textile business in our country is a profitable investment. Bed linen has always been in high demand. Blankets and pillows are purchased by all people, regardless of their financial situation. These products, unlike other textiles, do not depend on fashion trends, which allows you to avoid unnecessary costs for attracting designers to its development. The main changes can only concern the filler of bedding, which does not require the modernization of production equipment. According to research data, the textile industry produces about 40% of the total volume of industrial products.

To create a sewing production for the production of bedding, you will need a room with an area of ​​about 100-150 sq. meters. Keep in mind that blankets and pillows are a fairly large, albeit light, product, so in addition to the workshop, you will need separate premises for warehouses for finished products and consumables.

Of all the bedding sets, duvets are the hardest to produce. As a rule, blankets are purchased for a long time, so consumers have strict requirements for their quality. A wide selection of blankets is presented on the Russian market, which differ in season (lightweight summer blankets, demi-season blankets for autumn and spring, warmed winter blankets), density, sizes (for children, one-and-a-half, double blankets), filler. The sizes of blankets may vary depending on what standards are adopted in a particular country.

For example, in our country there are double quilts of the following sizes: euro (200 x 220 cm), which is most widespread throughout the world, "English" or "Soviet" size (175 x 205 cm), which is very popular in our country, euro-maxi or king - size (220 х240 cm). Slightly less common are double blankets measuring 180 x 210 cm.In Germany and Italy, for example, the most common are square blankets measuring 200 x 200 cm. Standard sizes one-and-a-half blankets - 143 x 215 cm and 150 x 200 cm.Children's blankets are produced in sizes 110 x140 cm, and blankets for newborns are 120x120 cm in size. In addition, you can find models of non-traditional shapes and sizes on sale - round, oval of various diameters. But in most cases they are made to order, as they are only suitable for certain beds.

The blanket manufacturer's assortment should include models for different seasons. For example, summer blankets are the lightest. Demi-season a little warmer. They are used in spring and autumn time of the year. Winter blankets are considered the warmest. Often, such models are labeled, depending on their heating properties. For example, one dot might represent lightweight blankets for warmer seasons and five dots for colder seasons. The warming qualities of a product depend on the density and type of material from which it is made. And the latter determines the price of the product.

There are the following types of blankets: blankets with open wool (made of dressed skins, winter and summer woolen blankets and blankets), blankets with filling (cashmere, camel, merino, silk, double silk, fur and lyo-purpose), synthetic blankets (polyester, polyester, acrylic).

The most common in our country are blankets with fillers. And the most expensive among them are cashmere products, which are made from a rare natural material collected by hand. The cashmere fabric is pleasant to the touch, perfectly retains heat, does not cause allergies and is practical to use. In second place are "closed" blankets with camel hair. This raw material consists of coarse hairs and a soft undercoat. For the manufacture of bedding, both harder wool is used (as a rule, sheared from adult animals), and softer with a large admixture of fluff (it is collected from non-working camels, and it costs much more than coarse wool). The camel hair is first combed and then quilted with the top and bottom layers of the fabric. And in fact, and in another case, the creation of one blanket requires a lot of wool, which determines its high cost. The advantages of such products are their good warming qualities. Merino lambswool blankets are just as warm and slightly less light, and they are cheaper than camel wool blankets.

The technology of thermal bonding of wool is often used in the production of woolen blankets. The raw material is coarser wool, which is cheaper than down. It is mixed with synthetic bristles. Then the resulting formation is driven between two heated shafts. Under the influence of high temperature, the synthetic material melts and reliably "glues" the woolen fibers, turning the base into a woolen layer. Some manufacturers save on natural wool and produce heat-bonded blankets, which are mostly made of synthetics.

Down duvets are made from natural white or gray goose down, eon or duck down. The most stringent requirements are imposed on products made of down. They must fully comply with Russian GOST. For the production of down bedding, the raw materials are collected first. White geese down is more prized as these birds live in colder regions and have thicker plumage.

For the production of products of a high price category, pure goose down of vivo plucking without admixture of small feathers is used. After the raw materials have been collected, they are sorted by fluff content, and sometimes by color, and refined. In the process of preliminary cleaning, hard flight feathers and remnants of a fender liner, crushed feathers and feathers without an awn are removed from the raw materials.

The sorted nib is washed, treated with an antistatic agent and disinfected in a special solution. It includes a feather wash shampoo that removes grease and prevents feather felting. Then they are rinsed, squeezed in a centrifuge and dried in a damper at a temperature of about 90 degrees Celsius. This is necessary in order to remove all living organisms from the plumage of birds, pathogenic viruses and bacteria. This stage is carried out extremely quickly, since the pen does not withstand prolonged exposure to high temperatures and may deteriorate. Immediately from the cooling chamber, the feathers are sent to sorting, where they are divided into fractions. On modern production this process is automated.

Then a batch of raw materials undergoes laboratory technical control, as a result of which the quality of the filler is checked. The proportions in which it is mixed are determined by the requirements of GOST. After sorting, the finished mixture, tested by specialists, goes to the stuffing shop for filling into bags. Small manufacturing companies prefer to buy ready-made mixtures from suppliers, do not carry out laboratory quality control of the packing of their products, save money on rent by renting a room with a smaller area.

The duvet cover is made from natural strong fabrics that are breathable and absorbent. On the other hand, they prevent fluff from coming out of the cover. Most often, these covers are sewn from satin, knitwear, cotton with the addition of lyocell, cambric, silk or jacquard using a special stitching with an inner piping, which prevents the fluff from penetrating outward. After filling the covers, the almost finished blanket is sent to the sewing industry.

According to the method of sewing, the following types of blankets are distinguished, which do not depend on the type of filler: cassette, quilted and carostep. The most reliable are considered to be cassette-type blankets, which, as mentioned above, are sewn in separate sections (cassettes). Each cassette with filler is isolated from the rest, which allows you to hold the "content", not allowing it to lose shape or stray into lumps inside the case. At first glance, a carostep trim looks like a pattern or decorative pattern on the surface of a blanket, which is why it is also often called a patterned stitch.

The main disadvantage of this sewing method is that the filler can come out through the holes that remain on the fabric after the needles. The quilt is sewn with a stitch on special machines, which prevents it from knocking down to the corners. There are two main ways of quilting - squares and parallel stitches. A quilt quilted in the form of squares is considered to be of better quality and more durable than a product sewn with parallel stitches. At the last stage, the blankets are packed in dense polyethylene bags, where labels are also placed, and sent to the warehouse.

Natural and environmentally friendly filler such as bamboo or eucalyptus fiber is gaining more and more popularity. These materials are highly breathable, absorb moisture, hypoallergenic, do not collect dust, have antistatic and antibacterial properties and increased wear resistance. Of course, bamboo fiber (like eucalyptus) is not harvested from the plant in its pure form.

First, a soft core is removed from the stem, which is successively treated with steam and pressure, resulting in cellulose. For production, only untreated bamboo is used not older than 3-4 years. The resulting cellulose is processed into yarn, from which bamboo cloth is woven. For sewing covers of inexpensive blankets, including those with bamboo filler, teak is used - a dense fabric of a plain weave type, which does not allow the filler to migrate outward. In more expensive types of blankets, satin is more often used - a fabric with diagonal threads and less often other, more exotic types of fabrics (for example, from the same bamboo fiber).

One more natural material which is used to fill pillows and blankets is silk. It is possible to list its advantages for a long time, including hypoallergenicity, resistance to creasing, the ability to prevent the formation of fungus, the reproduction of pathogenic microbes and dust mites, etc. The only drawback of silk as a filler is its high price. As a rule, two types of silk fibers (silk) are used for bedding - mulberry and tussa. Strictly speaking, only Mulberry variety can be called real mulberry silk. This silk has three quality classes A, B and C. The best material is class A, which is also called long-staple mulberry silk.

Sometimes, as a filler, the silk of the wild silkworm, which lives in natural conditions, is used. This kind of silk is called tussah. The cocoons of this silkworm are reddish-brown in color and require bleaching, as a result of which the structure of the silk is disrupted and its best qualities are lost.

Quality silk blankets are made by hand. First, small blanks made of silk are stretched to the desired size, and then layers of fabric are laid on them cross-to-cross. A Euro-maxi summer blanket weighing 1200 grams takes about 50 layers of silk. Long-staple, evenly laid silk forms a uniform, strong mass that is sewn onto the duvet cover. Silk quilts are cheaper because they are usually filled with Tussa silk and are not sewn by hand, but with the help of machines.

Synthetic blankets, unlike woolen and down products, are hypoallergenic, durable, lightweight and compact. They are made from cheap materials, which results in their low retail cost. But there are also disadvantages. The synthetic winterizer, which is often used as a filler for blankets, does not fall off and does not form lumps. However, this material is practically non-hygroscopic and poorly breathable. The body does not "breathe" under such a blanket, and it is possible to sleep under it only in very cold rooms. New generation polyester material (holofiber, komfortl) is more expensive than padding polyester, but supports well temperature regime allowing air to pass through and not accumulating dust.

One of the main specialists in the production of such products is a technologist. The process of making high-quality pillows and blankets has many nuances, and it is very difficult to find masters of their craft. Therefore, most companies abandon the idea of ​​organizing a full production cycle, purchasing ready-made raw materials on the side. They themselves only sew covers for products, fill them and pack them.

For the production of bedding you will need special equipment... You may need cutting tables or machines, edging equipment, a work table for bedding blankets, a trimming machine, for edging, for rewinding fabric at a 45 degree angle, quilting machines with program management for blankets, machines for processing polyester fiber into filling for pillows and blankets, dispensers for production duvets, germicidal installations for down and feather pillows, sorting machines for the production of down, a dispenser for filling down duvets, a line for the production of a blanket layer, packaging machines, etc.

The exact list of equipment you need depends on the types of products you will be producing. Both new and used equipment can be purchased. The minimum set for the production of items of 2-3 types will cost 1 million rubles. Sewing equipment for making bedding is produced in Russia, China and Europe.

In addition, there is an opportunity to purchase a ready-made tailoring business. For example, the production of mattresses, pillows and bed linen with a promised monthly profit of 300 thousand rubles and an average monthly turnover of 3 million rubles with a total of 20 employees is offered for sale at a price of about 10 million rubles. In such a production line, lines for the production of blankets, pillows, mattresses, cutting equipment, sewing machines and overlocks are installed. The leased area for such a workshop is about 350 sq. meters at a rental cost of 40 thousand rubles per month, plus monthly utility bills in the amount of 10 thousand rubles. The wages fund for a staff of 20 people is 150 thousand rubles a month. The production of only bedding (without mattresses) will cost 1.5-2 million less. However, with such production volumes, it is recommended to produce not only blankets and pillows, but also to sew bed linen, including sheets, pillowcases, duvet covers, mattress covers, etc. In this case, the payback period for production with a high profitability of up to 50% is about three years.

Lily Sysoeva
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Human sleep is such a mysterious and unexplored phenomenon that for many scientists it becomes a matter of a lifetime, about which they write treatises, conduct long scientific disputes, and hold symposia. If you do not talk about some individual characteristics of the body, then any insignificant detail can disturb sleep, for example, an uncomfortable bed, a light that has remained on, lumps on a sheet or blanket, and also much more that can poison existence.

Choosing a way to solve the problem

If there are any serious sleep disturbances, then it is necessary to contact a professional. And when the problem lies on the surface, you can try to solve it yourself. Many succeed in this. First you need to analyze in what state you go to bed every day.

Even if you are just a little nervous, you can become a hostage to your fears and worries, because of which the dream will definitely be disturbed. A terrible headache awaits you in the morning, which can also affect your appearance. On the part of relatives and colleagues, questions related to your circles under the eyes may appear.

Your bed plays an important role in good, deep sleep. Everything should be such that you can feel like a master in your bedroom, not a slave acting in favor of fashion trends. Everyone knows that nothing is more pleasant and more comfortable than a duvet and blanket.

They keep warm excellently, which is good in winter, when it is cold around and warm in the bed. In addition, they are so comfortable and enjoyable that it would be simply a crime to part with them. The production of down pillows and blankets is still quite a popular business today.

Exists different kinds blankets, you need to choose a specific one to start its production. The main difference between these products is the filler, on which the convenience of use and the resulting heat depend. Each consumer chooses for himself the kind of blanket that suits him the most, and you, as a manufacturer, need to navigate the modern needs of buyers in order to start making a product.

Duvet blanked

This type is the warmest and lightest, because down is a natural filler. The duvet has very good thermoregulation, so it is not hot under it in summer, and warm in winter. Despite the fact that the fluff is treated with antiallergenic impregnations, people suffering from severe allergies should refrain from such an acquisition. Making down duvets is the most difficult process.

Blanket

If you choose the production of such products, then you should know that they are characterized by almost all the advantages of down, but they are heavier. However, this point depends on the preference of the consumer. And the lanolin content in wool blankets makes them healthy.

Cotton blanket

The advantage of such products is their low price, hypoallergenicity and good warming properties. The disadvantages can be considered a tendency to absorb odors, reduced durability. However, many consumers choose just such products for themselves, so it makes sense to produce them.

Synthetic blanket

Now on the market there are a lot of fillers of synthetic origin, but their properties are not very different. Polyester has become the most popular filler at the moment. Blankets made of it are unpretentious to use, they can be machine washed, they are warm enough and do not tend to absorb odors. Due to poor thermoregulation, such blankets can become a real punishment for the consumer, since when it is cold or hot in the house, it will be uncomfortable underneath.

Basic moments

Of course, you can start your own business in the production of products stuffed with down, but at the moment there are alternatives such as synthetic winterizer and holofiber. These are very simple and fairly cheap bedding fillers. Making pillows and blankets using these fillers can be very profitable. Gradually, you will be able to receive tangible income.

So, if you decide to start the production of pillows and blankets, then you should first formalize the legal side of the issue. Only having received permission to organize entrepreneurial activity, you can count on peace of mind. After that, you can open and equip your workshop without fear of receiving any fines.

What is necessary?

To open a workshop, where the production of blankets and pillows will be carried out, a room with an area of ​​one hundred twenty - one hundred thirty square meters will be required. It should have good electrical wiring, as well as a place to store raw materials. The current rules prescribe the mandatory presence of a bathroom and a washbasin.

You can start the production of blankets and pillows if you have technical specifications registered in the department of state standardization. You can compose them yourself based on the acceptable specifications.

Cushions

Blankets are meant to just keep you warm. There is a more important attribute for sleep. Making pillows is a very important activity, as it is this attribute that can turn relaxation into pleasure or torture. They can be filled with the same materials as for blankets. Consumer preferences in this case are also very different. Some people buy small pillows on which only the head fits, and for some it is important that the pillow is huge and warm. If your business is making pillows, then hotels and hotels can serve as points of sale in this case. The main thing is to find an approach to the management of these institutions.

Our production includes a full cycle: from the manufacture of fillers on carding machines to the production of packaging, which ensures high quality of products with minimum costs... In the production premises on an area of ​​3500 square meters, on modern high-tech equipment of domestic and foreign production, highly professional employees with vast experience are on duty.

TECHNOLOGICAL PROCESS OF MANUFACTURING BLANKETS

CAMEL WOOL

The most commonand in our country there are blankets with fillers. One of which is camel hair. This raw material consists of coarse hairs and a soft undercoat. For the manufacture of bedding, both stiffer wool is used (as a rule, sheared from adult animals), and softer with a large admixture of fluff (it is collected from non-working camels). Wool arrives at the enterprise in compressed bales, having previously passed the cleaning and disinfection process.

Raw materials come with an accompanyingand documents - a veterinary certificate confirming the quality of raw materials. Before starting work at the enterprise, wool undergoes an incoming inspection, after which the raw materials are mixed, combed and subsequently a layer is made, which is rolled into a roller. The density of the finished bed is periodically checked.

In production, for the manufacture of camel wool blankets, the fabric is used - teak (100% cotton). The fabric comes in rolls, with an accompanyingand documents - quality certificate. Before starting work, the fabric is checked for compliance with the density (140-145g / m2), for defects and defects. After checking, the fabric goes into production.

For the production of classic blankets, the fabric is taken to work in the cutting shop. Blanket covers are cut from it. Then the cut goes to the sewing workshop. Here are qualifiedThe seamstresses assemble a semi-finished product from the parts, which is subsequently transferred to the printing and stitching workshop. At the next stage, the cover is stuffed with raw materials (a finished layer of appropriate density), evenly distributing over the entire area.

The hole for stuffing is sewn up and transferred to the quilting machine, where the blanket is semi-finishedThe kat is fixed in the hoop and the equipment is started, on which the quilt is stitched (the filler is combined with the upper and lower layers of fabric) in a given pattern. After stitching, the quality of the blanket is checked and sent to packaging.

For the manufacture of lightweight blankets, the fabric is wound on bobbins, which are subsequently installed on a multi-needle quilting machine and, passing a filler (of a certain density) between two canvases, form a quilted double-sided fabric.

At the next stage, this canvas is cut to size and edged on special. machines "SEIKO" and "Durkopp Adler". Then the blanket is checked for quality and packaged. The packaging is also produced by our company.

As part of the rolling research of Roskachestvo, the parameters of the quality and safety of products were studied 27 trade marks pillows. These are products under the trademarks AlViTek, Asabella, Belashoff, Comfort Line, Dream Time, Dargez, Ecotex, German Grass, Green Line, IKEA, Kariguz, Mona Liza, Nature's, Ol-Tex, Primavelle, Sortex, Togas House of Textiles , Verossa, A "Elite, Horizon, Every day, Light dreams, Lazybones, Pillow, Pierrot, Samson, TekStil. The study involved pillows, most popular among Russians, with and without covers, filled with synthetic fibers, as well as mixtures of such fibers with artificial fibers. Pillows of all price categories, produced both in Russia and abroad, were tested. The cost of the products that participated in the test is from 150 to 4,000 rubles at the time of purchase. But what are the best pillows to buy?

Russian quality system standard

The Roskachestvo standard, in comparison with the current GOST, has tightening in terms of the parameters of the linear dimensions of the product, the content of free formaldehyde and the resistance of the paint to various influences. In addition, additional quality indicators were included in the Roskachestvo standard, according to which the samples presented in the rolling study were evaluated. Such indicators are: specific surface electrical resistance and a change in linear dimensions after wet processing of the upper fabric, the absence of a noticeable smell of the product.

The required level of localization of production for the awarding of the Russian Quality Mark to a product is at least 45% of the cost of the product.

Neutral, acidic or alkaline?

To all known meaning pH from advertisements characterizes acidity or alkalinity aqueous solution... A pH level of 5.0 to 7.5 is considered safe for human skin. With a deviation to the big side, we can talk about increased content in an alkali solution, to a lesser extent - acids. The pH level for bedding has not been standardized by the current standards in Russia until recently. The Roskachestvo standard puts forward such requirements for pillows for the first time, since these products regularly and for a long time (on average, sleep lasts 7-8 hours) are in contact with the delicate skin of the face. In order to establish the pH level in the fabrics of the upper of the garment, experts in the laboratories obtained an aqueous extract from each sample. As a result of the research, a deviation of pH from the requirements of the increased Roskachestvo standard was revealed in six products. In each of the identified cases, the pH value exceeded 7.5 units, which indicated an increased alkalinity of aqueous extracts of the investigated products.

One product was found to be non-compliant with leading standards. We are talking about cushions of the Dargez brand, in which elevated level pH. Despite the fact that this indicator is not standardized by law in any way, it is provided for by the Roskachestvo standard.

In the course of laboratory tests, each of the samples was also determined: the toxicity index of materials, indicators of color fastness to various influences, odor intensity and the presence of free formaldehyde in tissues. According to the results of the study, the indicated parameters in all samples were within the normal range.

Smoking is harmful

"Smoking in bed is the cause of fire." This simple rule in Russia is included in any brochure on fire safety. At the same time, the fire resistance of bedding is not standardized in any way by the standards in force in the country. Roskachestvo, also for the first time in Russia, introduced such a requirement in its own standard. The study of the flammability ability of products was carried out in the framework of the so-called "cigarette test". During this test, a lighted cigarette was placed on a pillow for 7 seconds. If during this time the fabric did not ignite, the test was considered passed. Almost all pillows in the study were successful in this test. Only one sample, produced in China, did not pass the "fire" test. The pillow caught fire quickly enough to obtain the status of a product "related to highly flammable", which means that it did not meet the increased Roskachestvo standard.

Sleep hygiene

The hygroscopicity indicator is responsible for the microclimate of sleep; it determines the ability of products to absorb moisture. In the case of pillows, low values ​​for this parameter will lead to the fact that a person will wake up with a wet or damp head, which is unpleasant, unhygienic and even unsafe for health. The index of hygroscopicity of the fabrics of the top for pillows, as well as for fabrics of the top of blankets, was toughened by Roskachestvo by one and a half times. Most of the samples presented, with the exception of one product, met these increased requirements. But according to the results of independent laboratory tests, experts named goods under trade marks as unsafe products, whose indicators are below not only the Roskachestvo standard, but also the mandatory indicators of technical regulations. Pillow, Pierrot, Every day.

Effective area

The dimensions of the pillows and the aspect ratio are not regulated in any way by the current technical regulations. That is, the manufacturer can produce pillows of any size under one condition: information on the linear dimensions of the product on the labeling of such products must be reliable. Otherwise, consumers will have trouble “packing” a pillow into a pillowcase. Moreover, these difficulties can arise even when the actual size of the product differs from the declared one by only 1–2 centimeters. The dimensions of their products were incorrectly indicated by the manufacturers of the following products: AlViTek, Belashoff, Comfort Line, Ecotex, Ol-Tex, Pilushkino, Pierrot, Every day, IKEA. In some cases, the deviation on one of the sides was 3 centimeters. Obviously, with such a discrepancy, the pillow will freely "walk" in the pillowcase or will not fit into it, which is unlikely to be liked by consumers. All discovered facts of non-compliance with the declared sizes are regarded as a violation of consumers' rights to reliable product labeling.

AFTER REPEATED RESEARCH

Pillows of the AlViTek Belashoff and IKEA brands, the actual dimensions of which, according to the results of the previous study, differed from those indicated in the marking, now correspond to the declared dimensions.

100% natural lie

Today pillows are filled with various natural, artificial and synthetic materials. People sleep on products "stuffed" with latex, buckwheat husks, medicinal herbs, hay and even algae. Recall that pillows filled with synthetic fibers took part in the research of Roskachestvo - this is the most popular category of products among Russians. It has many advantages: for example, such pillows are hypoallergenic and relatively cheap. It is worth noting that recently consumers are increasingly paying attention to products that are sold in covers - it is more convenient to wash them. These covers, in turn, just like pillows, have their own filling and upper fabric. According to the laws in force in Russia, the manufacturer must accurately indicate the composition of all "components" of the product. As a result, the difference from the real composition was found in the goods of the following brands: Comfort Line, Ecotex, Green Line, Horizon, TekStil, A "Elite, Sortex, Verossa, Samson. Some of these manufacturers have proven to be particularly resourceful. So, sample packaging under the trademark Green line She "promised" that the filler of the cover will consist of 90% natural fibers, in fact, it consisted of 100% polyester fibers. Also from 100% polyester fibers was made to fill the Horizon pillow, declared as "made from 100% wool". Manufacturer Sortex By labeling his product he reported that the filler of the cover was made of 50% cotton. Reality is 100% polyester fiber. All the indicated facts can be considered as a violation of consumers' rights to reliable labeling. Information about each detected case of falsification was sent to the relevant control authorities.

AFTER REPEATED RESEARCH

Ecotex pillows, which previously had a discrepancy in the marking not only in the declared dimensions, but also in the raw material composition of the textile materials included in the pillow, have also been corrected.

The overwhelming majority of the items studied had the so-called "fantasy names". The products were called "Linen", "Linen and Cotton", "With sheep's wool", "Merino" (sheep breed), etc. As a rule, "prints" (photo collages and drawings) on such pillows were used with corresponding images and images of plants or animals. In fact, all the samples presented in the study were filled with polyester fibers, which have nothing to do with wool or flax. Roskachestvo recommends that buyers carefully study the information on the composition of the product and pay less attention to bright packaging. Although sometimes even the specified composition does not guarantee that the product will actually be made from the "promised" materials.