How Pillows Are Made

Summary

This video script details the manufacturing process of synthetic fiber pillows, highlighting two styles: garnet and blown. It showcases machines that comb and straighten fibers, reduce static with a special solution, and create fluffy, crimped-free fibers. The process includes forming flat sheets, merging them into thicker webs, and cutting them to size for pillow filling. The video also covers the automated creation of cotton or cotton blend pillow shells, which are then filled with the prepared synthetic fibers and packaged for retail.

Takeaways

• 🧶 Synthetic fiber pillows come in two styles: 'garnet' with rolled fibers and 'blown' with loose fibers.
• 🔧 The pre-opener machine uses a steel spiked roller to comb and separate the fibers, but not fully.
• 💨 Nozzles spray a special solution to reduce static electricity, preventing fibers from clinging together.
• 🌀 Garnet pillows use fans to blow fibers through a duct to another opening machine for further combing.
• 🔄 The garnet hopper machine further combs the fibers, making them fluffier, straighter, and smoother.
• 🔗 The next opening machine uses metal rollers with sharp ridges to stretch and straighten the fibers, removing crimps.
• 📏 The fibers are then formed into flat, fluffy sheets called 'webs', which merge to create a thicker web.
• 🔲 The lapping machine builds the web into the desired pillow width by layering it back and forth.
• ✂️ The continuous web is cut into pieces and rolled into a 'bat', determining the pillow's firmness and height.
• 👕 An automated machine makes the cotton or cotton blend shell, which is then prepared for the filling process.
• 🏭 The shell is filled with the bat, compressed, and packaged, completing the pillow production.

Q & A

What are the two styles of synthetic fiber pillows mentioned in the transcript?

The two styles of synthetic fiber pillows are 'garnet' and 'blown'. Garnet pillows are filled with a roll of synthetic fiber, while blown pillows are filled with loose synthetic fibers.

What is the purpose of the pre opener comb machine in the production process?

The pre opener comb machine is used to comb the synthetic fibers with a large steel spiked roller, which separates them to a considerable extent, though not yet fully.

How does the special solution sprayed by nozzles affect the fibers?

The special solution sprayed by nozzles is used to reduce static electricity, which prevents the fibers from clinging to each other.

What is the function of the garnet hopper in the pillow production?

The garnet hopper feeds the fibers onto a spiked conveyor belt, which combs them out further, removing many of the remaining crimps.

How does the next opening machine help in straightening the fibers?

The next opening machine uses several metal rollers with sharp ridges to stretch the fibers straight, removing the remaining crimps.

What is a web in the context of the pillow production described in the transcript?

A web is a flat, fluffy sheet of fibers formed when the fibers pass over one of two rollers in a specific machine.

How do the two webs merge to form a thicker web in the production process?

The two webs merge as they exit the machine, forming a thicker web, which is then lapped back and forth over itself to build an even thicker web.

What determines the width of the pillow in the production process?

The width of the pillow is determined by the width of the lapping, which is the process of the machine lapping the web back and forth over itself.

How does the length of the rolled piece affect the characteristics of the pillow?

The length of the rolled piece determines the characteristics of the pillow. The longer the rolled piece, the fatter and heavier the bat, which translates into a higher and firmer pillow.

What is the role of the automated machine in making the cotton or cotton blend shell?

The automated machine is responsible for creating the cotton or cotton blend shell that will encase the bat. It mounts two identical rolls of fabric onto the machine's cradles and feeds the ends through a series of tension rollers.

How is the product information label attached to the pillow shell during production?

The product information label is sewn onto the pillow shell after the machine mates two rectangles, stitches them together on three sides to form a shell.

Outlines

00:00

🛏️ Synthetic Fiber Pillow Production

The script describes the manufacturing process of synthetic fiber pillows, which come in two styles: garnet and blown. Garnet pillows are filled with a roll of synthetic fiber, while blown pillows contain loose synthetic fibers. The process begins with a pre-opener machine that combs the fibers using a steel spiked roller to separate them. A special solution is sprayed to reduce static electricity, which helps prevent fibers from clinging together. The fibers are then blown through a duct to another opening machine, the garnet hopper, which further combs them. The fibers are further processed through a series of machines that stretch and straighten them, removing any remaining crimps. The fibers are then formed into a web, which is lapped back and forth to create a thicker web, determining the pillow's width. The web is cut into pieces and rolled into a 'bat,' which determines the pillow's characteristics such as height and firmness. The cotton or cotton blend shell is made separately and then combined with the bat. The final product is filled with the bat and packaged for retail.

Keywords

💡Synthetic fiber

Synthetic fibers are artificially made fibers, typically from petrochemicals, and are used in various industries including textiles. In the video, synthetic fibers are the primary material for the pillows, being processed and manipulated to achieve the desired texture and softness. The script describes how these fibers are combed and treated to remove crimps and achieve a fluffier, straighter, and smoother appearance.

💡Pillow styles

The video discusses two styles of synthetic fiber pillows: 'garnet' and 'blown.' Garnet pillows are filled with a roll of synthetic fiber, while blown pillows contain loose synthetic fibers. These styles differentiate the types of pillows based on their filling method, which affects the pillow's firmness and support.

💡Pre opener

A pre opener is a machine used in the textile industry to prepare fibers for further processing. In the video, the pre opener combs the synthetic fibers with a large steel spiked roller, which helps to separate and partially straighten the fibers. This process is crucial for the subsequent steps in creating the pillow filling.

💡Static electricity

Static electricity is the electric charge at rest, which can cause fibers to cling together. The script mentions that nozzles spray a special solution to reduce static electricity, ensuring that the fibers do not stick to each other and can be properly processed. This is important for maintaining the quality and consistency of the pillow filling.

💡Garnet hopper

The garnet hopper is another opening machine mentioned in the script, which further combs the fibers to remove any remaining crimps. It is part of the process that transforms the fibers into a fluffier, straighter, and smoother form, suitable for garnet pillow filling.

💡Web

In the context of the video, a web refers to a flat, fluffy sheet of fibers formed by the opening machines. The fibers pass over rollers that create two webs, which then merge to form a thicker web. This web is crucial for building the structure of the pillow, as it determines the final thickness and softness of the pillow.

💡Lapping

Lapping is the process of folding a web of fibers back and forth over itself to build an even thicker web. The width of the lapping determines the width of the pillow. This technique is used to create the desired dimensions for the pillow, ensuring that it has the right size and shape.

💡Bat

A bat, in this context, refers to a rolled piece of the continuous web of fibers that will be used as the filling for the pillow. The length of the piece determines the characteristics of the pillow, such as its height and firmness. Longer rolled pieces result in fatter and heavier bats, translating into higher and firmer pillows.

💡Cotton or cotton blend shell

The shell of the pillow is the outer covering that encases the filling. The video describes an automated machine that makes the cotton or cotton blend shell, which is then used to case the bat. The shell is crucial for the final product as it provides the pillow with its shape and protects the filling.

💡Overlock stitch

An overlock stitch is a type of sewing used to prevent the edges of fabric from fraying and to provide a strong, durable seam. The video mentions that the machine uses an extremely strong overlock stitch to sew the pillow shell, ensuring that the seams are secure and the pillow maintains its shape and structure.

💡Plastic retail packaging

Plastic retail packaging is used to protect and present the finished product for sale. In the script, the pillows are covered in their plastic retail packaging before the filling process, which helps to keep the pillow clean and ready for retail display. This packaging is an essential part of the product's presentation and preservation.

Highlights

Synthetic fiber pillows come in two styles: garnet and blown.

Garnet pillows are filled with a roll of synthetic fiber.

Blown pillows are filled with loose synthetic fibers.

The pre-opener combs fibers with a large steel spiked roller.

Fibers are sprayed with a special solution to reduce static electricity.

Garnet hopper further combs fibers, removing crimps.

Fibers are stretched and straightened by metal rollers with sharp ridges.

Two rollers form a flat, fluffy sheet called a web.

Webs merge to form a thicker web, determining pillow width.

Continuous web is cut into pieces and rolled into a bat.

The length of the rolled piece determines pillow firmness and weight.

Cotton or cotton blend shells are made for pillow casings.

Shells are made by mating and stitching two fabric rectangles.

An overlock stitch is used for the shell's stitching.

The bat is compressed and filled into the pillow shell.

Pillows are covered in plastic retail packaging before filling.

Transcripts

[Music]

these synthetic fiber pillows come in

two styles garnet meaning the pillows

are filled with a roll of synthetic

fiber and blown meaning it's filled with

loose synthetic fibers this first

machine the pre opener combs the fibers

with a large steel spiked roller this

separates them to a considerable extent

though not yet fully the fibers exit

this machine straighter and smoother

however several are still crimped the

pre openers four outputs drop the fibers

onto a conveyor belt which takes them to

the next opening machine along the way

nozzles spray a special solution to

reduce static electricity which causes

fibers to cling to each other to make

garnet pillows fans blow the fibers

through a long duct that leads to

another opening machine called the

garnet hopper it feeds the fibers onto a

spiked conveyor belt which combs them

out further this removes many though not

all of the remaining crimps after the

garnet hopper the fibers look like the

ones on the right

fluffier straighter and smoother the

fibers now travel to the next opening

machine it has several metal rollers

with sharp ridges which stretch the

fibers straight removing those remaining

crimps the fibers then enter yet another

machine passing over one of two rollers

each of which forms a flat fluffy sheet

called a web the two webs merge as they

exit the machine forming a thicker web

then the next machine laps it back and

forth over itself to build an even

thicker web the width of the lapping

determines the width of the pillow then

the machine cuts the continuous web into

pieces and rolls each one into what they

call a bat the length of the piece

determines the characteristics of the

pillow the longer the rolled piece the

fatter and heavier the bat which

translates into a higher and firmer

pillow an automated machine makes the

cotton or cotton blend shell that in

cases the bat workers mount two

identical rolls of fabric onto the

machines two cradles and feed the ends

through a series of tension rollers

because the two sheets must be taut as

they pass through the machines different

stations at the first one blades trim

the fabric to the correct width for the

pillow size standard queen or king then

a slitter runs across each sheet cutting

a series of rectangular pieces the

machine then mates two rectangles

stitches them together on three sides to

form a shell and sews on the product

information label

[Music]

the machine uses an extremely strong

overlock stitch now it's time to fill

the shell as the bat travels on a

conveyor belt another belt above

compresses it as it enters the waiting

shell covered just beforehand in the

pillows plastic retail packaging

[Music]

[Applause]

[Music]