Bates Mill - Loom to Heirloom process

Production line of looms at Bates Mill Factory

Recently, M and I took the most amazing tour of the Bates Mill Factory in Monmouth, Maine.  We were blown away by welcoming atmosphere and fantastic access to the factory floor.  We got so many great pictures and documented the entire "Loom to Heirloom" process so we wanted to share it with you!



Bates Mill Factory Tour - K getting up close to the weaving process

Step 1 - Yarn Mill
Cones of cotton yarn are wound onto large steel spools called section beams.  Then multiple section beams are wound onto a larger steel spool called a warp.  It takes nearly 2 million yards of cotton yarn to fill the largest size warp.




Bates Mill Factory Tour - Yarn Mill



Step 2 - Weaving
Each strand of yarn from the warp is tied onto the loom (a process that can take up to 8 hours).  The pattern is set up on the loom either electronically or with the classic punch cards.  Warp yarn feeds in to the loom vertically while the yarn known as the weft feeds in horizontally.  The loom control sits above the ceiling lifting and dropping the heedless to create the design.  The fabric is wound onto a continuous roll as the loom weaves.



Bates Mill Tour -  Clockwise from top left.  Weft yarn is added horizontally.  Weaving info sign. Rolls of loomed fabric.  Production line of looms in action, notice the warp roll slightly above each loom and the heedless going up to the ceiling where the loom control is reading the pattern.  Front view of loom, you can see the pattern of the fabric and the continuous roll being generated.

 

Step 3 - Finishing
The Finishing departments consists of three  different steps: cutting, stitching and washing.  The rolls of fabric are cut into the individual bedspreads.  Stitchers apply the fringe finishings or plain hems to each bedspread


Bates Mill Tour - Clockwise from top left.  Heavy Duty blade used to cut the roll of fabric.  Fabric coming off the loom roll to be cut on the cutting table.  Finishing info sign. Cutting table, in the foreground is the track that cutting blade is pushed across to make the cut.  Employees adding edging and sewing hems.


Step 3.3 - Washing and Drying
All items are laundered in order to both soften and preshrink the cotton.  You can really see how loose the weave is before washing.



Bates Mill Tour - Unwashed example on the right, washed on the left.  The unwashed sample is stiff and the weave very open.  The washing process softens and shrinks the weave.

 
Steps 4 and 5 - Inspection and Shipping
A team of two inspect each item to make sure it meets Bates high quality standards.  Items not passing are repaired.  Once packaged the bedspreads are shipped around the world.




Bate Mill Factory Tour - Inspection, packaging and shipping



What step do you find most interesting?  Would you be interested in taking the Bates Mill tour?