The Process

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HOW YOU CAN HELP

Most importantly, clean your fleece as much as possible before shearing! Use a blower or flicker to get as much debris out of the coat as possible immediately before shearing, and always shear on a clean surface. Skirt the fleece to remove any debris, second cuts, and inferior fleece before sending it to be processed. Specifically, remove any sections of fiber that ‘crunch’ when you squeeze them.  Throw out any sections that are urine-soaked or clumped with poo.  If you remove areas with a lot of guard hair (seen as a halo of longer fibers), your yarn will be softer & less likely to prickle. This will reduce your costs for postage and the percentage of weight lost in processing. Please do not send fiber under 3″ or over 7″ long if you want yarn.  Shorter fiber can be made into batts, felts, rug yarn, or blended with longer fiber for regular yarns. Fiber over 7″ long simply wraps our machines and gets torn up. Please do not send Suri cria fleece, unless it is to be blended with other fiber. Some Huacaya cria blankets can be processed, but most Suri cria fiber is too weak.  Please note that yarn made with weak fiber is prone to little lumps & bumps…a great novelty yarn, but not appropriate for commercial knitting or weaving. Please check all your fiber for tenderness (weakness).  Take a small lock (about 50 hairs) and pinch the ends between your thumb & forefinger of each hand.  Snap your hands apart.  If the fiber breaks, it is too weak to process alone.  A strong fiber should make a ‘poing’ noise and not break.

THE PROCESS

All fiber is hand washed and dried, then goes through the picker to open the fleece to prepare for carding. If you would like to blend any other fiber with your fiber, it will be added at this point. Please ask us if you would like any alpaca or wool blended with your fleece. We have several colors available. If you have any other fiber you would like to blend, please call us to discuss specifics.  We simply don’t have enough room to store all the possibilities! Next, the fiber is carded and combed into a beautiful sliver for hand-spinning. The roving is neatly bagged, ready to spin. If spinning is not your thing, we can then process the roving into yarn or hand spin it – simply ask for details. We are now offering a core-spun yarn, commonly called ‘rug yarn’!  Choose either a thin core or a thicker core for the results you prefer! Our finished yarn is available in any thickness you want. For best results, send us a sample of the size yarn you desire. Please visit the Craft Yarn Council to learn the proper terms if you are unfamiliar with grist: http://www.craftyarncouncil.com/weight.html We can make cabled yarn, singles, 2-ply, 3-ply or 4-ply yarn. Any and all special requests are welcome! Here are the steps to get from raw fiber to beautiful yarn. Please click on an image to view a larger version.

Tumbling

Fiber TumblerAfter weighing your incoming fiber, we tumble it. The fiber is put into a screen drum and rolled for a few minutes to shake a lot of the loose dirt, short second cuts & debris out of the fiber. This makes the fiber easier to wash and puts less dirt into our septic tank.

Washing

Fiber WasherAll incoming fiber is washed before we process it. Although alpaca fiber does not contain lanolin, it is still very dirty with sweat & oils from the animal’s skin. We wash the fiber in very hot water in a special washer, as agitation will felt the fiber into an unusable mass. We use biodegradable detergents specifically made for scouring fiber. Unlike large, commercial mills, we do not use toxic chemicals to dissolve the vegetable matter (VM).

Drying

Washed fiber drying on racksOnce the fiber has been washed, it is spread out on racks to dry, usually overnight. We do not use heaters to force the fleece to dry quicker, as it could over dry and weaken the fiber.

Picking

Going into the PickerOnce the fiber is completely dry, we feed it through the picker to open up the locks & ready the fiber for carding. The fiber may be picked a couple times, depending on how well it fluffs up and if we are blending different fibers or colors. We then correct the fiber to 20% moisture content and add spinning conditioners to improve the elasticity of the fiber and to help it hold together better. The low scale height of alpaca and mohair that makes them so soft also makes it harder to spin them than wool, so we add a little ‘hair gel’ to help!

Carding

Separating before cardingOnce the clumps are removed in picking, and the fiber is at the correct moisture level, it is carded. Carding is a fascinating process! Not only does the card separate the fibers, it also drops out most of the VM and a lot of the coarse, straight guard hairs. Most of the second cuts that made it this far are also dropped out. We are very excited to show you  pictures of our new carder, delivered in October 2013!  She is a real workhorse, and produces a lovely, fluffy product.  Can you guess why her name is Lucretia Borgia? Ramella Carder - Roving OutThe fiber comes out of the carder in the form of a thin sheet, called a web. This web is then wrapped around a drum to form batts or run through a pair of rollers to form a loose tube, often called roving. We can also drop the web directly into a bag to return a beautiful cloud for hand-spinning or felting.

Drafting

Pin Drafter - Incoming fiberAlpaca fiber does not form a nice, solid roving like sheep’s wool does. We run all roving through the pindrafter once, which combs and drafts the fibers into a nice, smooth stream. It is easy to spin, and doesn’t require splitting or pre-drafting like some top does. Handspinners love it!   Pin Drafter - Outgoing sliver   For yarn, we  usually draft the fiber three times, more for suri and superfine yarns. This means the fibers are very smoothly aligned, resulting in a lovely sliver to be spun into a semi-worsted yarn.

Spinning

Spinner - Incoming sliversSpinning is a very involved process, combining precise mathematical calculations and a ‘feel’ for the qualities of each individual batch. A fleece may vary greatly in staple length, fineness, strength and other qualities that affect ‘spinnability’, which may require adjustments to the thickness of the sliver & the amount of twist used. The spinner is tuned to each batch individually. Spinner - Bobbins at workAs the sliver is fed into the back rollers, it gets flattened out in the blue apron, and then is teased out by the fast-moving front rollers. At the same time, the bobbins are spinning below, twisting the yarn as soon as it comes from the front roller. The spun fiber is then wound onto the bobbin as a ‘single’. Singles are often used for commercial sock knitting, weaving, or are sent on for plying.

Plying

Most yarn and even thread is plied. Plied yarns are several singles twisted together to form a thicker and stronger yarn. We have a 12-head twister that loves to act up when no one is looking:  VM often snags the singles & throws bobbins off the machine, hitting me in the head!

Spinner - Spun yarn plyingThe most common misconception we come across is people who think that 2-ply is a size of yarn. It is simply the number of singles in the yarn. Both laceweight yarn and mop string can be 2-ply yarns.

We generally prefer a 3-ply yarn, as it is a rounder, fuller shape than the DNA-like helix of a 2-ply. We also prefer to use several plies to make a bulky weight yarn, to avoid the appearance of mop string & to increase strength.

However, we make lace yarns in 2 plies.  The time needed to spin a yarn increases dramatically as the thickness decreases and the twist increases, so the finer the yarn, the longer it takes.

Skeining or Cone Winding

Skein WindingAfter plying, we usually wind the yarn off the bobbins into skeins. Skein size is completely up to the customer. We default to a 300 yard skein as it is a nice manageable size for all but the bulkiest yarns. If you prefer, we can wind the yarn onto cones for ease of use in knitting or weaving. Cones are a lot easier to manage when using a lot of yarn, and don’t roll around & tangle like balls can.

Yarn Washing

Skeins of yarn dryingAlthough we try to get the fiber as clean as possible during washing, it is never perfect. As the fiber processes through the mill, it picks up more dust. We wash the finished skeins again, to remove the dirt, spinning aids, and to bloom & finish the yarn. If balls are desired, we then wind the skeins into center-pull balls for ease of use. The yarn is then returned ready to use or to sell! As coned yarns are wound onto paper cones, we cannot wash coned yarn.  Simply wash your project when you’re done creating – don’t forget to wash your swatches!