CARDED FABRICS PRODUCTIONS

Every year in Prato approx. 22000 tons of rags with a peculiar process typical of the district are converted into yarn and then into fabrics.
This is being done all in the Prato’s area. These are THE CARDED WOOLEN FABRICS.

Prato district is known all over the world for being able to produce these kind of fabrics.

WHAT IS RECYCLED WOOL?

Recycled Wool called also “ MECHANICAL WOOL” because of the methods rags are treated to be brought back to status of Fiber.

This particular treatment of rags became the tradition of Prato’s fabrics industry since late 50’s.
Recycling process and carded fabrics are strictly connected.

In other words, a recycled fiber can be only spun on a carded spinning machinery, as this is the only way to get a proper yarn for the fabrics.
We always talk about RECYCLED WOOL, but also more precious fibers such as Cashmere can be RECYCLED.

NELLO GORI CARDED FABRICS

Our production is mainly based on carded wool, or on more lux fibers blended with synthetic fibers to produce nice basic classical piece dyed or heather fabrics, luxury finishing, in different weights suitable for men and ladies outwear.
Then we got a wide range of yarn dyed fancy fabrics , fashionables items such as printed, flocked, bonded and coated fabrics, developed to satisfy younger fashion requirements.
We have always been very sensible to technological innovations focused to increase performances of our fabrics.
In our range you will find also good examples of qualities with special treatments such as Droptex and Raintex fabrics, Antipilling, Antistatic and Antistain fabrics.

WHAT CARDED PRODUCTION PROCESS IS

As already mentioned,this is a very peculiar production process which allows to recover second hands clothing and textile waste of new fabrics used in garment industry.
The important feature of this process is that it can use short fibers and different lengths, in blends of the different compositions.
The result is a yarn with a particular aspect that distinguishes it from the other type of yarn known as WORSTED.
Reprocessed wool provided for over a century a phenomenal opportunity for the development and the growth of the textiles Prato’s District on world markets.
The techniques of this “ recycling process “ are fascinating to be observed but also prove that Prato got a culture for the respect of the environment, for human resources and shows a tradition of skill and professional business initiative.
Recycled fibers lost some of their appeal in recent years because of discovery of synthetic fibers and the growing demand for virgin fibers partly in response to the expanding economies and to new consumer request.
Since price for Virgin Wool has strongly increased in the last few months, recycled wool could be a good alternative to get nice woolens fabrics at competitive prices.
Hereunder, we try to give you a very basic summary of the recycling process :

Rags (textiles and knit waste and second hand clothes ) are stocked in big warehouses to be manually sorted by specialized workers by color and kind of fabrics ( knits or woven ) as recycling process is not exactly the same for knits and woven fabrics.
Zips, Buttons and Linings are eliminated.

The material is then washed and dried.
Afterwards it goes throught a special cutting machinery to be ripped.

Once ripped it goes to carobonising where, thanks to sulfuric and hypochloric acid solutions, all vegetable fibers are destroied.

After beating also the smallest contaminations disappear.
Rags are now back to the original state of “fibers” ready to be spun on the special carded spinning machinery and become a yarn to be woven into fabric again.
Today this same process can be carried out on precious animal fibers such as Cashmere, Alpaca, Angora,
Mohair Yarn obtained from recycled material can either be 100% animal fibers or blended with silk, viscose , or polyamide .