How it works

Production Process: How Pillows Are Made

 

The Kariguz pillow, blanket and bed linen factory was founded 21 years ago on the site of the Russian-Latvian goose farm and inherited its name, which stands for "Kashira - Riga - Goose Factory". "Kariguz" is one of the 10 largest manufacturers of bedding with down feathers in Europe in terms of technical equipment and production capacity. In the assortment of "Cariguse" - more than 1,500 items of goods. In addition, down-processed fluff is purchased by manufacturers of down jackets for climbers.

 

Scientific and Production Corporation "Cariguz"

 

FACTORY LOCATION

Kashira district, pos. Big Runovo

 

date
discoveries

1993 year

 

number of employees

500 people

 

ANNUAL
turnover

About 400 million rubles (SPARK)

 

For the production of pillows and blankets "Kariguz" is mainly used goose feather, which comes from the northern regions of Russia. Before passing a truck with raw materials to the factory, the veterinarian checks the accompanying veterinary documents. Then the truck passes through the gates equipped with air barriers. Raw material bags are weighed and transferred to a sealed ozonizer chamber for disinfection. Then, several feathers from each bag are taken for analysis in the laboratory, in which the quality indicators of the incoming batch of raw materials are determined.

 


 

After disinfection, the veterinary service checks the batch, and only after that the raw materials go to the primary processing. At this stage, the removal of mechanical impurities.

 


 

Then the operator loads the raw materials into the sink: with a strong stream of air it is drawn into the pipeline leading to the machine.

For one wash cycle of the pen, which lasts at least two hours, the washer rinses 60 kg of raw material. This procedure ensures that there is no odor, grease or dirt in the filler. The process uses active oxygen and natural wax to preserve the natural properties of the material. After washing, the raw material is squeezed out, discharged into the drive, and then it goes into the dryer. Then the semi-finished product is subjected to antimicrobial heat treatment at a temperature of 130 degrees for 40 minutes.

 

 

After drying, the pen enters the cooler, and then is unloaded in bags or piped directly to the secondary sorting.

 



 

Recycling takes place in special machines made of plywood - thanks to this, the raw materials are not electrified from the effects of static electricity. In them, with the help of air currents, large, medium, small feathers and down are separated. Each of the fractions settles in one of the successively arranged chambers through which the pen flies. The more such cameras, the better the fluff will be.

 


 

In the sewing workshop sew covers for pillows and blankets. A small hole is left in each product through which they are stuffed with a feather and down.

 


 

So pillows are stuffed. The cover is fixed on the pipe leading to the storage machine, each of which is made for its own semi-finished product: down, half-down, feather. On the weighing scales, the weight of the future pillow is set, the feather and down are fed through the pipe. Filling stops when the balance fixes the required weight. The operator removes the pillow, weighs it on a control scale and gives the seamstress so that it sews up the hole. Then the pillows are placed in a blower to remove the remaining fluffs and prepare for packaging.

 


 

Cassette blankets are stuffed a little differently than pillows, although the system is the same: storage machine, dispenser scales, a large needle instead of a pipe. The difference is that the drive stuffs each cell separately, and not the entire blanket at once. The process takes place automatically - the operator only controls the correct filling of each cartridge.

 


 

Another option is the production of cassette-type blankets: the operator stuffs the blanket manually, then lays it on the surface of the quilting machine and evenly distributes the filler. Then the car makes a blanket.

 

 

When the products are ready, they are placed in an automatic packaging machine, and then served in a warehouse. For a shift, the factory produces about 3,000 pillows and 100 blankets.

 

Photo: Maria Minkova

Watch the video: How Pillows Are Made (December 2019).

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