Processes

The Spinning Process

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Dyeing
NZ Yarn Ltd dyes its own wool and other fibres in the loose stock stage in large batches to ensure colour match consistency. Hank dyeing is also undertaken. Dyes used are of the highest standards of fastness and are stringently checked by colourists before further processing

Blending
Dyed stock is transported from the dyehouse through pneumatic conveyors to the blending system, where the fibres are thoroughly mixed to enusure a uniform colour throughout every batch.

Carding
From the blending, wool is passed to the carding section. The 10 modern woollen cards operate on a 24 hour basis keeping a continuous supply of wool to the spinners.

Spinning
High production ring spinning frames spin the yarn to meet individual customer specifications.

Twisting
Yarn is twisted into 2, 3 and 4 ply on ring twisting frames to a wide range of twist levels.

Hanking
High speed hanking machines, set at pre-determined meterages, produce hanks which are ready for scouring or bailing.

Scouring
NZ Yarn is a leader in the field of yarn scouring and setting technology. According to the specified characteristics of the finished yarn, scouring and setting, as required, is achieved either by the TAPE SCOUR method in hanks, or by the continuous package to package “CHEMSET” process.

The CHEMSET Process
In 1986 the business commissioned the world’s first-ever CHEMSET continuous yarn scouring and setting machine. Yarn chemically set by this process is manufactured by many of NZ Yarn’s customers into “Saxony” and ”Freeze” style, cut pile, tufted carpet which exhibit unique tuft definition, resulting in improved appearance retention in the finished carpet

CHEMSET has enabled the commercial developments of printing and continuous dyeing of wool carpets from a natural wool base.

How it works

Yarn is taken from two banks of 12 bobbins or packages and coiled, or run through 2 MF4 Superba Freeze units, into two continuous blankets which then undergo scouring, setting and moth proofing treatments before they are dried and wound back on to cones. Computer control units accurately determine the meterage per cone, thus producing the exact number of units to match each individual customer’s creel loading requirement. Finished cones of yarn from either process – CHEMSET or tape scour method – are packed in plastic bags, weighed and customer labelled for dispatch.