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The Process to Make These Organic Cotton Sheets
| Sheets &
Pillow Cases | Duvets &
Shams |
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The cotton used is grown organically. This means that
the seeds must be non-genetically engineered; insects are controlled by methods
that simulate what occurs in the natural environment, where "good"
bugs eat "bad" bugs. There is also be an emphasis on keeping
plants healthy- healthy plants are more resistant to infestation-fields are
usually weeded by hand. Organic farms are not allowed to use any chemical
fertilizers or chemical inputs, such as herbicides or other pesticides.
These standards are set forth by the International Federation of Organic
Agriculture Movements (IFOAM). |
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The organic cotton for our organic cotton sheets and duvets
are grown in three developing countries-India, Turkey, and Uganda on
family farms that range in size from 2 to 250 acres. Purchasing
cotton at a better price per pound, we help support local and economically
sustainable production. |
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After
the cotton has been picked, it is ginned to removes the seeds from
the cotton fiber (lint). |
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The lint is then baled and sent to the mill where it
is spun into yarn, which is then woven into fabric. It is a state-of-the-art
facility with computerized looms and the best spinning equipment available.
Just as important, the facility is ISO (International Standards
Organization) 9002 certified-which speaks well for both the quality of
production and its labor and environmental practices. |
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At the mill, the cotton is carded so that the fibers
are aligned. It also separates out the longest and strongest fibers from the
weaker, shorter fibers. |
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The carded cotton is then ring spun into yarn. This
process makes it softer. |
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Next, the yarn is woven into fabric. To do so it is
immersed in a wheat-starch solution, a sizing, which both strengthens the
yarn and makes it easier to weave. |
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From here, the ecofinishing process begins. Finishing
removes the wheat-starch sizing, cleans, softens, and then pre-shrinks the
fabric so it feels and looks "finished." Some of the fabric is put
through a hydrogen peroxide bleaching process to whiten it. Up until this
point neither our cotton fiber, yarn, or fabric has come into contact with
any chemicals. A number of chemicals are used in the various steps of
finishing, only chemicals that are approved by certifying organizations,
both in the US and Europe are used.
 | Pre-shrinking itself is a wholly
non-chemical process that involves pulling and stretching the fabric
using rubber pads and steam. Pre-shrinking molds the fabric to its final
measurements. |
 | All the chemicals used in this process are
water-soluble.
 | An Amylase enzyme removes the wheat starch sizing. |
 | Two
detergents, one an anionic surfactant and the other a fast wetting
agent, clean the fabric. |
 | A defoamer controls the sudzing of
the detergents |
 | A soy lecithin is used to soften the sheets
at the end of the process. |
 | Whitened fabrics are also treated
with Sodium silicate. A sequestering agent and Ph stabilizer that
aids the bleaching process. Caustic soda removes the natural wax
from the yarn and activates the peroxide. |
 | A non-ionic
surfactant acts as a cleaning agent and silicate dispersant. |
 | Bleach
(hydrogen peroxide) whitens the fabric. |
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