The very first stage of the velvet dyeing process is actually to buy in the untreated - or 'loom-state' - fabric from various Lancashire Weavers. Only the very finest loom-state is brought in.
We can cater for literally any length you need - whether you want 500 metres
or just enough for those new curtains! At this stage of the process the fabric
still has quite a rough feel so it needs to be thoroughly washed and
to have all loose fibres and lint removed.
The velvet itself is actually two pieces of fabric woven together and then cut laterally right through the centre. This very precise and exacting process is what creates the familiar 'pile' finish that we all love. You can see the two faces clearly on the right.
After a thorough washing the velvet is then slowly fed through the dye. Here
at Story Velvets we employ the very latest computer-controlled technology to
ensure the dye is applied evenly and that the dye temperature is kept consistent.
It is of course essential at this stage to get the exact colour match our customers have requested. If there is even the slightest discrepancy in colour matching the dye machines will be halted and the correct dyes added.
This exacting task is performed by our master dyers. And they are righly proud of their craft - after all, when you're dealing with twenty shades of blue this level of colour-matching requires the very keenest eyesight. It also requires a thorough knowledge and experience of dye technology so that just the right amount of dye is added.
The fabric now needs to be dried and stretched into shape. Our two enormous drying machines stretch the material and make it dimensionally stable as it runs through the powerful four-stage heating ovens.
At this stage we apply the special resins and softeners - environmentally friendly of course - which helps the velvet to resist creases, and encourages creases that do occur to drop out. Depending on our customers' requirements, flame-retarding solutions can also be applied during the drying stage.
The velvet is then drawn through a series of rollers that have literally tens of thousands of tiny pins on them. This last process lifts the pile of the fabric to an evenly upright state - but at a slight angle. This slight angle is important because velvet 'pile' will either reflect or absorb light depending on the angle it is viewed from. It is this property that creates velvet's familiar finish.
The very last stages of the process are carried out by our quality-control inspectors.
We are proud
to guarantee that no product will ever leave our factory unless it is in perfect
condition and ready to give years of service!
IMPORTANT:
If you intend to use our velvets for making curtains then we very strongly recommend that you make them 'pile up'. In other words, the velvet should only 'ruffle' as you run your hand down the fabric - not up.
Doing this correctly allows the velvet pile to gradually drop down - thus building a natural lustre and depth over time. For advice on this important point please call our office in Rochdale.
Please also note: Every single shade of Story Velvets has an exact reference number as you will see on the 'order sample' page of this website. It is important that you ensure you have quoted the correct reference number if/when you request any of our free samples.