Pufpaff's Fiber Processing Nashville, MI 517-852-1871

Photo 1 The fiber is prepared by washing, dyeing, carding and blending it into batts. These batts come off the carding machine by being wound onto a drum that creates multiple layers.  After the batts have rested for at least 24hours, the layers are pulled apart in preparation for being put into position.	Photo 2 The separated layers from the batt are place next to each other on a mosquito netting covered work surface.
Photo 3 A second layer of fiber is placed perpendicular to the first layer to strengthen the felt fabric.	Photo 4 With both layers in place, the layout is checked for inconsistencies and any adjustments needed are made by adding or shifting fiber
Photo 5 When the entire layout has been inspected and corrected, the mosquito netting is wrapped around the fiber to assure that everything stays in place	Photo 6 The netting covers the fiber bottom, top and sides.
Photo 7 To transport the fiber to the machine, the net-encased fiber is rolled around a PVC pipe. No moisture has been added to the fiber at this time.	Photo 8 The machine will handle up to 30 feet of net encased fiber. The working width of the machine is 36 inches.
Photo 9 The dry, net-encased fiber is then loaded into a cotton casing belt on the bed of the felting machine.	Photo 10 As the net-encased fiber is loaded, the cotton casing is adjusted to make sure it completely covers the project.
Photo 11 When the project is completely inside the casing, the PVC pipe is removed.	Photo 12 Final adjustments are done to the net-encased fiber and the cotton casing.
Photo 13 The rollers are lowered onto the bed of the machine.	Photo 14 After the rollers are lowered, the machine is started slowly and as the casing travels through the machine, soap and water are added to the fiber.
Photo 15 The speed of the machine is then increased, the oscillating plate is engaged and the casing continuously travels around the machine until the fibers are firmly holding together.	Photo 16 After the fibers are firmly holding together, the upper rollers are lifted from the bed of the machine, the cotton casing is opened and the felt fabric is removed from the netting
Photo 17 The yardage is wound around a PVC pipe to simplify removal and reloading	Photo 18 The netting is completely removed from the yardage.
Photo 19 The felt fabric is turned so that it can be reloaded onto the machine bottom-side-up and end-for-end.  This encourages the fibers to move more freely in the fulling stage of the process.	Photo 20 The felt fabric is reloaded into the cotton casing belt making any adjustments needed in the fabric itself and in the casing to assure the quality of the finished fabric.
Photo 21 The rollers are then lowered back down onto the bed of the machine. The machine is again brought up to speed and the oscillating plate is engaged.  The fabric loaded inside the cotton casing continuously cycles around the machine until the felt is harden to the desired consistency.	Photo 22 The machine is stopped, the rollers are lifted and the fabric is removed from the cotton casing.
Photo 23 The fabric is placed in a washing machine to be rinsed and to extract the water.	Photo 24 The now rinsed, damp felt is removed from the washer.
Photo 25 The yardage is stretched and hung from custom drying racks in a climate controlled drying room.	Photo 26 Drying is complete in just a few hours. After drying, the yardage can be cut and sewn into garments, fashion accessories home decor items and much more.