"Soft knops" wool process developed

Waimarino Bulletin, Volume 5, Issue 23, 3 November 1987, Page 6

"Soft knops" wool process developed

The Wool Research Organisation of New Zealand has developed a new process for the manufacture of a unique wool fill product, known as "soft knops". It will initially be used in bedding - pillows and duvets - and as a filling for upholstered furniture. The product was officially launched on the market by the Minister of Trade and Industry David Caygill at a function held in October in the Woolfill NZ factory which has been built at Sockburn by a private company, specifically to produce the new wool fill. The process uses short, coarse wools and is an ideal use for short second

shear wool which is often in lower demand. WRONZ researchers have adapted an existing machine known as an "opener" - used for teasing wool prior to carding - to develop the process. Modifications include the addition of a micro-proces-sor to automate the process which involves graduated feeding of the wool through a revolving drum where it is beaten by "teeth" to bend the fibres and form them into small spherical balls. These are next given a solvent scouring to remove residual grease, then sanitizing, mothproofing and shrinkresistant treatments. The end product has many advantages over similar

fills such as fibre wadding and synthetics. Because the fibres are bent and locked into each other, the knops have greater bulk and resilience. They are very light, about one-third of the weight of wool. Items can be blow-filled with soft knops which avoids problems of "cold spots" along the stitching experienced when conventional fills are sewn into the cover. Items filled with knops are readily shaken or plumped back into their original shape. An item such as a pillow will compress only where the weight of the head lies, which gives greater support for the neck and shoulders and moulds round the head. The product retains the fire resistant qualities of wool, and is able to absorb moisture - up to 30 percent of its volume by weight - without actually feeling damp. The WRONZ Textile

Physics group headed by Dr Garth Carnaby began working on the development of the new process about 18 months ago. Ian MacFarlane, a scientist in the group started the idea and worked with Woolfill NZ to perfect the process, experimenting with various treatments, temperatures and modifications of machinery to come up with a product of "reasonable" quality late last year. Work has continued in conjunction with Woolfill NZ to bring it up to commercial quality and during this period WRONZ continued to carry out part of the process at its test workshops in Lincoln. Although it is only a few weeks since the last of the modified machines was transported from Lincoln and installed at the new factory, commercial quantities of soft knops are already being produced. The main end user is Slumberwool, which is marketing the knops as "Snuglets" in a range of luxury pillows.