How Pillows Are Made
Summary
TLDRThis 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
🛏️ 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.
Mindmap
Keywords
💡Synthetic fiber
💡Pillow styles
💡Pre opener
💡Static electricity
💡Garnet hopper
💡Web
💡Lapping
💡Bat
💡Cotton or cotton blend shell
💡Overlock stitch
💡Plastic retail packaging
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]
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