How are the ALVEN fabrics made?
ALVEN fabrics are woven in Italy. The Italians have mastered an art of weaving that has been lost in many, if not most, European countries or is no longer practiced for economic reasons: The complex jacquard technique.
ALVEN bed linen are usually made in Jacquard and chambray satin in matching colours. The jacquard looms can weave patterns up to 300x300cm in size. Theoretically one could weave a single duvet with only one large motif, but the waste of fabric in the sewing process would be substantially (there are always small weaving errors in the fabric).
First the yarn is threaded - see picture above. It runs from a variety of spindles:
Many ALVEN fabrics are woven in two colours. The design "Lej da Staz" has a neutral dyed warp (longitudinal thread) and a beige or light blue weft (cross thread). This results in a discreet or, with other designs, stronger pattern.
The fabric comes in a very long web from the loom and is then first washed:
After weaving and washing our fabric is not ready yet. In order to soften it, burn off excess fibres and give it the beautiful shine that our customers appreciate, it is gassed and calendered in a next step:
The rolls shown in the picture (there are several) are very hot. The damp fabric is pulled over and smoothed.
At the end of the process, the fabric web is also used for quality assurance. On a large, well-lit, vertically inclined table (like a large canvas), the fabric is checked very carefully and small weaving faults are marked on the edge. Later on, in the ready-made department, the best possible attempt is made to leave out the weaving faults by cutting them to size in order to produce as little scrap as possible.
So it takes a lot of work to make the bed linen. You can also read our blog post on the hand making of our bed linen.