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.