Our Unique Production Process
The secret of Texeler
Texeler combines pure wool with the latest and most advanced and unique production techniques. The pure wool from the Texeler sheep is famous for its warmth and ventilation. The lanolin (wool fat) ensures that the wool fibers remain flexible and resilient. With the best machines and a unique needling system exclusive to only the Texeler factory, Texeler creates products that allow you to experience the beautiful qualities of wool every day in your own bed.
The Texeler Sheep Breed
The history of the Texeler sheep dates to around 1850. The animal was mainly kept for milk and wool at the time. Texel breeders further developed the breed. In 1909, the breed description was included in the Texel Sheep Studbook. The 'Texelaar' was born (but we will refer to it as the Texeler Sheep)! The Texeler is the ultimate sheep, boasting the finest wool coat of fine fibers. The rougher the climate, the better the wool.
The high humidity on the island of Texel, combined with salty sea winds, has resulted in a particularly long curly coat with a remarkably high content of lanolin (wool fat). Due to this long curl, the wool of the Texeler has a unique thermostatic regulation; it retains heat very well and ventilates. The bedding is therefore nice and cool in the summer and warm in the winter. The wool of the Texeler sheep is a natural product and is particularly suitable for use in duvets, underblankets, pillows, and futons.
Sheep Shearing
The sheep are sheared each spring by experienced professionals who prioritize animal welfare. The sheep are calmly gathered, and each one is carefully relieved of their heavy winter coat—a process that actually benefits the sheep by keeping them comfortable in warmer weather.
Texeler works exclusively with skilled shearers who treat every animal with care and respect. These professionals can shear approximately 150 sheep per day, spending an average of 4 minutes per sheep to gently and safely remove their full fleece. The sheep are never harmed during this process—shearing is a natural, stress-free experience when done by trained experts. The sheep walk away unharmed, cooler, and more comfortable for the summer months ahead.
The Production Process
1: Beginning of the production process
Upon arrival at the factory, the wool is inspected and then carded. This untangles the fibers. Carding is done with a comb with steel points. Machine carding is done with a fast-rotating cylinder equipped with steel points or even a needle bed. With carding, the last remnants of dirt are also removed and disposed of in the special "dirt vacuums" that are above the carding machine. After carding, spinning can be done immediately if desired. However, for a finer result, the wool must first be combed. To obtain better regularity in the final yarn, various stretching and doubling passages must also be applied, whereby the thread becomes increasingly regular and thinner.
2: The unique needling process
Due to the climate on Texel, Texeler sheep have a longer coat than any other sheep breed: a particularly long and curly fleece with a remarkably high content of lanolin. After the carding process and the wool fleeces are made, they are needled. This unique system, which is only applied at the Texeler factory, ensures that the wool is needled vertically, resulting in an even more airy, ventilating, and resilient product. Compared to "normal" wool duvets, Texeler's needled duvet feels much lighter and has much more resilience.
3: Sewing the cover and wool together
After the wool has been scoured, the fleece is rolled into large rolls and attached to the sewing machine that sews the wool and cover together. A good cover must, of course, be lightweight and supple. Once the choice of cover has been made, it is sewn together with the processed wool. All of this is done on the various sewing machines present in the factory operated by skilled people. The most advanced machine is computer-controlled and can incorporate logos or other patterns into the duvet. The temperature and humidity are always closely monitored during production so that the wool can be processed optimally.
4: Packaging the bedding
When the bedding is finished and carefully inspected, it is packed in a bag. Depending on the type of bedding, it is packaged in the appropriate bag. The bag is equipped with handy handles so that the bedding can also be taken on vacation. If there are multiple bedding pieces, the bags are packaged in matching boxes that are tailor-made. These boxes are then placed on a pallet and sealed so that transportation will not damage the bedding.
5: To the customer
Once the final product is ready, it can be ordered. There are many possibilities to create the desired product for the customer. WarmWool takes care of the entire process from start to finish. Thanks to many years of experience in the export industry, you can be assured that WarmWool will deliver the products safely.
