Focus: Goose down processing

In our previous article, we discussed the types of feather and the characteristics of goose down. In this piece, we will talk you through goose down as raw material and share how it is processed in our production facility.

Goose down finds its deserved value both for its quality at the time of purchase as raw material and as a qualified product due to the thoroughness and technological approach involved in its processing. The quality of the product is further revealed by cleaning the down from dust, the quality of the water and shampoo used for washing, and the innovative approach used throughout the production line.

In our 52 thousand square meter high-quality production facility with cutting-edge technology, we have the capacity to wash 800 tons of goose down and feather per year. As a leading goose-down pillow and duvet producer in Turkey, we remain the first and only Turkish company to have a say in the field of goose-down as a filling material. Since we are the only Turkish corporate member of the European Down and Feather Association (EDFA), we also keep tabs on the developments in the field. With our knowledge about the stages of production of washed down and feather, we offer consultancy to companies focusing on goose down, from sleeping products to furniture, clothing to exclusive products, and become their solution partners in production.

Following their import from Europe, raw goose down and feather are cleaned of dust and washed using a special goose down shampoo at 30 to 40°C. After that, they are dried at 70 to 90 °C for hygiene purposes and dust absorption is performed again for final disinfection. Then, down and feather are separated. They are quality checked, followed by packaging and shipping.

Stages of down and feather production

Preliminary Preparation and Finishing

• For washing, clean water from 130 meters below the ground is used instead of tap water.

• The water to be used for washing is first softened and filtered.

• 80 tons of water is kept to ensure steady supply.

• In line with our sustainability principles, the water discharged to the sewage system is treated and regularly tested.

Check out the image below for the process flow chart

The Arrival of Raw Material and Pre-Dusting

• Raw materials arrive at our plant pre-washed or fully-washed.

• They arrive in bales of 350 to 400 kg or 20 to 30 kg sacks.

• They are put and rotated in giant tumblers to rid large-sized dust particles. • Our technology and expertise in dust removal is Nomite certified. This certification assures that the filling is mite-free.

Washing

• For washing, down and feather are separated into batches of 180 to 200 kg.

• The washing cycle consists of 1 wash followed by 3 rinses.

• A total of 16 thousand liters of water are used in each cycle, 4 thousand liters per batch.

• The water temperature is kept between 22 to 25˚C.

• An industrial hair shampoo type of washing agent is used.

Preliminary dusting and washing chart

Drying and Cooling

• Drying is carried out in batches of 45 to 50 kg.

• At the beginning of the process, the humidity is between 22 to 24%, dropping to 5 to 6% at the end.

• The temperature is increased to 120˚C to disinfect the down and feather.

Drying and Cooling chart

Sorting

• Goose down and feather undergo sorting through 3 chambers.

• By adjusting the speed and amount of air circulating between the chambers, the maximum distance the down and feather can reach is determined.

• The heaviest ones are collected in chamber 1 while the lighter ones remain in chamber 2.

• The lightest, which is the down, go all the way up to chamber 3.

• To produce more lightweight products, down can be preferred for duvets as feather is heavier. In pillows, the selection and ratio of filling materials differ according to the desired density and properties.

Sorting chart

Shipping

• The chambers are directly connected to sacks.

• Sacks are weighed, lot numbers are written on them.

• They are shipped to relevant customers or to Maya Textile.

Shipping chart

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