Equipment for the production of pillows and blankets. Profitable business: production of pillows and blankets. Technology for the 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, which have many advantages. As a result, the manufacturing process has been greatly simplified and automated. bedding, which allowed to reduce the cost of organizing its own production.
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. This product, unlike other textile products, does not depend on fashion trends, which allows you to avoid unnecessary costs for attracting designers to its development. The main changes may concern only the filling 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 products manufactured in the industrial sector.
To create a garment production for the production of bedding, you will need a room with an area of about 100-150 square meters. meters. Keep in mind that blankets and pillows are a fairly large, albeit lightweight product, so you will need separate rooms for warehouses of finished products and consumables in addition to the workshop.
Of all bedding products, blankets are the most difficult to produce. As a rule, blankets are purchased for a long time, so consumers place strict requirements on their quality. On Russian market a wide selection of blankets is presented, which differ by season (lightweight summer, demi-season for autumn and spring, insulated winter), density, size (children's, one and a half, double), filler. Blanket sizes may vary depending on what standards are adopted in a particular country.
For example, in our country there are double blankets following sizes: euro (200 x 220 cm), which is most common throughout the world, "English" or "Soviet" size (175 x 205 cm), which is very popular in our country, euro-maxi or king - size (220 x240 cm). Slightly less common are double blankets measuring 180 x 210 cm. In Germany and Italy, for example, square blankets measuring 200 x 200 cm are the most common. Standard sizes one and a half blankets - 143 x 215 cm and 150 x 200 cm. Baby blankets are available in sizes 110 x 140 cm, and blankets for newborns are 120 x 120 cm. In addition, models of non-traditional shapes and sizes can be found 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 assortment of the manufacturer of blankets should include models for different seasons. So, for example, summer blankets are the lightest. Demi-season ones are a little warmer. They are used in the spring and autumn seasons. Winter blankets are considered the warmest. Often, such models are labeled, depending on their warming properties. For example, one dot might represent lightweight duvets for the warm season, and five dots for the cold season. 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: open wool blankets (from dressed skins, winter and summer wool blankets and blankets), filled blankets (cashmere, camel, merino, silk, double silk, fur and lyocell), 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, harvested by hand. 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 (usually sheared from adult animals) and softer wool with a large admixture of fluff are used (it is collected from non-working camels, and it costs much more than hard wool). First, the camel hair is combed and then quilted with the top and bottom layers of fabric. In both cases, the creation of one blanket requires a lot of wool, which causes its high cost. The advantages of such products lie in their good warming qualities. Merino lambswool blankets are just as warm and slightly less light, and they cost less than blankets made from camel hair.
Quite often, in the production of woolen blankets, the technology of thermal bonding of wool is used. The raw material is coarser wool, which is cheaper than fluff. It is mixed with synthetic pile. Then the resulting layer is driven between two heated shafts. Under the influence of high temperature, the synthetic material melts and reliably “glues” the woolen villi, turning the base into a woolen layer. Some manufacturers skimp on virgin wool and make blankets using thermal bonding technology, which are mostly made of synthetics.
Down duvets are made from natural down of white or gray geese, goose or duck down. The most stringent requirements are imposed on products made of down. They must fully comply with Russian GOSTs. For the production of down bedding, raw materials are first collected. The down of white geese is more valued, as these birds live in colder regions and have denser plumage.
For the production of products of a high price category, pure goose down of intravital plucking is used without the admixture of fine feathers. After the raw material has been collected, it is sorted by down content and sometimes by color, and cleaned. During the pre-cleaning process, stiff flight feathers and the remnants of the wing liner, crushed feathers and feathers without an awn are removed from the raw material.
The sorted pen is washed, treated with an antistatic agent and disinfected in a special solution. It includes shampoos for washing down feathers, which remove grease and prevent feathers from falling off. 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 high temperatures and may be damaged. Immediately from the cooling chamber, the feathers are sent for sorting, where they are divided into fractions. On modern productions this process is automated.
Then the 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, checked by specialists, enters the stuffing shop for filling into cases. Small manufacturing companies prefer to buy ready-made mixtures from suppliers, do not carry out laboratory quality control of the stuffing of their products, save money on rent by renting a smaller area.
The duvet cover is made from natural strong fabrics that are well breathable and absorb moisture. On the other hand, they do not allow fluff to get out of the case. Most often, such covers are sewn from satin, knitwear, cotton with the addition of lyocell, cambric, silk or jacquard using a special line with an inner piping that prevents the fluff from penetrating out. After filling the covers, the almost finished blanket is sent to the sewing production.
According to the sewing method, the following types of blankets are distinguished, which do not depend on the type of filler: cassette, quilted and karostep. The most reliable are blankets with a cassette assembly type, which, as mentioned above, are sewn together in separate sections (cassettes). Each filling cassette is insulated from the rest, which allows you to hold the "content" without letting it lose its shape or clump inside the case. Karostep trim, at first glance, looks like a pattern or decorative pattern on the surface of a blanket, which is why it is also often called pattern 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 quilted with a stitch on special machines, which prevents it from being knocked down to the corners. There are two main ways of quilting - square and parallel stitches. A blanket quilted in the form of squares is considered to be of higher quality and more durable than a product sewn with parallel stitches. At the last stage, the blankets are packed in thick polyethylene bags, where labels are also inserted, and sent to the warehouse.
Natural and environmentally friendly filler such as bamboo or eucalyptus fiber is gaining more and more popularity. These materials perfectly pass air, absorb moisture, hypoallergenic, do not collect dust, have antistatic and antibacterial properties and increased wear resistance. Of course, bamboo fiber (like eucalyptus) is not extracted from a plant in its pure form.
First, the soft core is removed from the stalk, which is successively treated with steam and pressure, as a result of which cellulose is obtained. For production, only raw bamboo is used, not older than 3-4 years. The resulting cellulose is processed into yarn, from which the bamboo fabric is woven. For sewing covers of inexpensive blankets, including those with bamboo filler, teak is used - a dense fabric of 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).
Another natural material that is used to fill pillows and blankets is silk. One can 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 fiber (silk) are used for bedding - mulberry and tussah. Strictly speaking, only the Mulberry variety can be called true 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 silkworm of a 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 broken and its best qualities are lost.
High-quality silk blankets are handmade. First, small pieces of silk are stretched to the desired size, and then layers of fabric are laid crosswise on them. About 50 layers of silk fabric are used for a summer Euro-maxi size blanket weighing 1200 grams. Long-staple, evenly laid silk forms a homogeneous, durable mass, which is sewn to the blanket cover. Quilted silk blankets are cheaper, as they are filled, as a rule, with Tussa silk, and are not sewn by hand, but with the help of machines.
Synthetic blankets, unlike wool and down products, are hypoallergenic, durable, light and compact. They are made from cheap materials, which leads to their low retail value. 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. Under such a blanket, the body does not "breathe", and you can sleep under it only in very cold rooms. A new generation of polyester material (holofiber, comforter) is more expensive than synthetic winterizer, but it supports well temperature regime, passing air 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 are abandoning 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 worktable for hooping blankets, a trimming machine, an edge trimmer, a 45-degree rewinder, computer-controlled quilting machines for blankets, machines for processing polyester fiber into filler for pillows and blankets, dispensers for the production duvets, feather pillow bactericide, down sorting machine, duvet filling dispenser, quilt ply production line, packaging machines, etc.
exact list necessary equipment depends on the types of products you will produce. You can buy both new and used equipment. The minimum set for the production of products of 2-3 types will cost 1 million rubles. Sewing equipment for the manufacture of bedding is produced in Russia, China and Europe.
In addition, it is possible to purchase ready business for tailoring. So, 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 staff of 20 people is offered for sale at a price of about 10 million rubles. Such production has lines for the production of blankets, pillows, mattresses, cutting equipment, sewing machines and overlockers. The leased area for such a workshop is about 350 square meters. meters at a rental price of 40 thousand rubles per month plus monthly utility bills in the amount of 10 thousand rubles. The salary 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 cheaper. 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.
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TECHNOLOGICAL PROCESS FOR MANUFACTURING BLANKETS
CAMEL WOOL
The most commonand in our country are blankets with fillers. One of which is camel wool. This raw material consists of coarse hairs and a soft undercoat. For the manufacture of bedding, both harder wool (usually sheared from adult animals) and softer wool with a large admixture of fluff (it is collected from non-working camels) are used. Wool comes to the enterprise in compressed bales, having previously passed through the process of cleaning and disinfection.
The raw material comes with an accompanyingand documents - a veterinary certificate confirming the quality of raw materials. Before starting work at the enterprise, the wool passes the input control, after which the raw material is mixed, combed and subsequently a layer is made, which is rolled up into a roller. The density of the finished layer is periodically checked.
In the production for the manufacture of camel wool blankets, teak fabric (100% cotton) is used. 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 verification, the fabric goes into production.
For the manufacture of classic blankets - the fabric is taken to work in cutting room. Covers for blankets are cut from it. Then the cut goes to the sewing shop. Here qualifiedThe seamstresses assemble a semi-finished product from parts, which later goes to the stuffing 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 stuffing hole is sewn up and transferred to the quilting machine, where the semi-finished blanketthe cat is fixed in the hoop and the equipment is started, on which the blanket is stitched (the connection of the filler with the upper and lower layers of fabric) with a given pattern. After stitching, the quality of the blanket is checked and sent for 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 sheets, form a quilted double-sided fabric.
At the next stage, this canvas is cut to size and edged onto a special. machines "SEIKO" and "Durkopp Adler". Next, the blanket is tested for quality and packed. The packaging is also produced by our company.
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Calculate shippingRussian production of pillows
The catalog contains pillow manufacturers in Russia. The list includes 110 companies for 2020. Production and wholesale sales are underway. Negotiated prices. Famous brands of the Russian market:
- "Nature's",
- dreamline,
- Kazanova,
- "Ormatek",
- "Agro-Don",
- Sewing enterprise "Tefiya",
- "Perrino" and other suppliers.
Domestic brands cover almost the entire market. Pillows with light swan down filling are popular. The fabrics of the top of the pillow and the cover are used - cotton, satin, calico, other textiles. Common materials - bamboo fiber, goose feather. The choice of product size - 68x68, 50x68, standard and euro, for children. Tailoring of goods to order on length and width is available.
Buy bamboo and down products in the bedrooms is available through the online store. Companies also produce bed linen, camel wool blankets, blankets, bedspreads, mattresses, mattress covers - so that the buyer can see good dreams! The production of new material is mastered. Furniture for pillows - beds, ottomans, sofas, etc. Production facilities carry out all-season promotions, discounts.
The manufacturer invites home goods stores and dealers to cooperate. The address, website, phone number of the companies are added to the "Contacts" tab. In order to buy products in bulk, download the price list - contact the manager. The list is updated constantly. Delivery by transport companies - Moscow and the region, regions of Russia, CIS countries and far abroad.
Ecology of consumption. Business: The production of pillows, mattresses, blankets with natural fillers does not require expensive equipment...
Modern life is filled with stress, which, of course, does not have the best effect on human health, in particular, on the quality of sleep. That is why pillows and mattresses with natural vegetable fillers, such as buckwheat and cedar, have become so popular lately.
The production of pillows, mattresses, blankets with natural fillers does not require expensive equipment, large industrial premises, highly qualified personnel. As a rule, it is enough to rent a workshop and a warehouse where raw materials and finished goods will be stored. Production equipment consists mainly of cutting tables (average price 10 - 12 thousand rubles) and sewing machines (price from 5 thousand rubles).
Products are sold in health goods stores, medical equipment stores, orthopedic stores, bed linen stores, furniture stores, as well as in specialized online stores.
Buckwheat pillows and mattresses
Buckwheat husk has the shape of pyramids, inside which there is air, thanks to which the pillow filled with buckwheat husks has good air permeability, maintains a constant temperature for a long time and absorbs excess moisture.
The skin and muscles are massaged during sleep with buckwheat pyramids, this relieves tension, helps to treat headaches.
Pillows and mattresses made of buckwheat easily take the shape of the body, this gives the correct position during sleep, which is also important for healthy rest and prevents the development of various diseases of the spine.
Many also like the natural aroma of buckwheat husks.
The husk is obtained after processing buckwheat. The harvest is brought to the groats, where the pre-steamed grain is separated from the fruit shell in a special drum for separation. The husk retains the shape of a pyramid during separation, and when it dries, it closes. As a result, hollow tiny boxes are obtained, which serve as an excellent filler for pillows and mattresses.
Cleaning the husk consists of four stages. First, straw fragments, sticks and other debris are removed, then calibration takes place, when whole boxes are separated from damaged ones, next buckwheat dust is removed, and finally the husk is steamed to disinfect and give it strength and elasticity.
The purification procedure is long and expensive, but it is necessary to create high-quality raw materials. Untreated husk crumbles and turns to dust during the first months of use.
It is worth buying husks only from reliable manufacturers, after making sure of the quality of the products. How well the husk is cleaned is easy to check: on White list paper you need to pour a handful of husks, and then carefully remove. If the sheet remains clean and there is no dust, then you have an excellent hypoallergenic material.
Husk for premium class pillows is packaged in packages and bags. The cost of a bag weighing 10 kilograms is 250 rubles. The volume of the bag is 0.1 cubic meters. With bulk purchases, the price per kilogram of husk can be 16-17 rubles per kilogram. The cost of delivery is easy to find out using the calculator on the website of a suitable transport company. Some husk producers offer paid delivery of goods to the regions.
It is very important to choose the right material for the pillowcase. The fabric should be thin, natural and breathable. Very beautiful and durable pillows are obtained from jacquard satin, a thin and soft cotton fabric with a dense weave. Jacquard satin is smooth and shiny, the husks in such a pillowcase spill freely, without clinging to the fibers. The cost of a meter of jacquard satin (width 280 centimeters) - from 500 rubles. Cheaper fabrics are also used: coarse calico, cotton, chintz.
Thus, Cost of materials, used in the manufacture of one pillow measuring 40x50, is about 100 rubles.
The cost of a pillow is also affected by:
- expenseson material delivery,
- employee salaries,
- rent,
- the cost of utilities.
Pillows made from high-quality raw materials cost from 500 rubles in retail. The price of a buckwheat mattress measuring 100 by 200 centimeters is more than 3,000 rubles.
In addition to mattresses, you can also produce mattress toppers that are cheaper, weigh less and take up very little space.
Various herbs, such as lavender, are added to buckwheat husk pillows, as the smell of natural lavender has a pronounced calming effect. Lavender oil evaporates instantly, so it is not used for the production of pillows, but dried lavender flowers retain not only a pleasant smell, but also healing properties for a long time.
Production of bamboo pillows and blankets
bamboo fiber- a unique filler for pillows and blankets. This is a material that is softer than cotton, and feels like silk or cashmere to the touch. Bamboo has high antibacterial properties and is well ventilated, so the bamboo bed gives coolness in the heat and perfectly warms in the winter.
The deodorizing effect of the vegetable filler prevents the appearance of unpleasant odors.
Bamboo pillows give a person a feeling of extraordinary comfort and provide good vacation during sleep.
Products made from bamboo fibers can withstand up to 500 washes without losing their shape.
The use of pillows and blankets made of bamboo fibers is recommended for children, the elderly and sick people.
To get fiber the soft core is extracted from the bamboo trunks, from which cellulose is then produced. Cellulose is processed into yarn, and already a valuable material is made from the yarn, which serves as a filler for pillows and blankets.
The fiber production process is 100 percent environmentally friendly, thanks to which all the beneficial substances found in bamboo are preserved in the fiber, including green pectin, which moisturizes and smoothes the skin of the face and neck, as well as tones and cleanses the skin, restoring energy metabolism.
Bamboo fiber is purchased, usually in China. The batch size is not less than 200 kilograms. The cost of a kilogram of fiber from the importer is from 200 rubles. Delivery within the country is made by car or by railway. Shipping cost depends on the weight and volume of the shipment.
store fiber should be in a clean and dry room, as a damp cloth is easy to deform.
Cotton, satin, bamboo, polyester-bamboo blend, etc. are used as fabrics for pillow covers and blankets. Standard pillow sizes are 40x40, 50x50, 50x70, 70x70.
The average cost of a pillow is about 300 rubles. Retail Bamboopillows cost from 600 rubles.
For the production of blankets ordinary sewing machine not enough - need a sewing machine. The cost of such equipment is approximately 150-180 thousand rubles. The use of a quilting machine can automate the sewing of blankets (production from 50 to 200 blankets per shift). The price of a quilting installation is from 600 thousand rubles. The investment will pay off within 6 months. published
