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At the beginning, Paylana exclusively operated as a wool
selection, scouring, drying and combing business, and
gradually, though in quite a short time, it turned into a
company with a vertical structure production process. At
present, the mostly stressed aspect is differentiation, which
may determine the weaves' finishing process. 100% of the
products is controlled at each stage of the process, thus
ensuring the excellent quality of the Company's weaves.
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Spining
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Weaving
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Finishing
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The basic operations in the manufacture of a combed weave
are: spinning, dyeing, weaving and finishing.
The plant is divided in the following production areas:
• weaves manufacturing area, which comprises the spinning mill,
weaving mill and weaves' finishing section.
• coloring area, duly equipped in order to dye tops, yarns in
their various forms and fabrics.
• knitting yarn area, in charge of producing yarns for
knitwear, scarves and socks manufacturers.
Spining
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process
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Spinning is a process which consists of transforming tops
into yarns. At present, tops are received as bumps or coils,
from which samples are extracted in order to carry out an
appropriate control. Afterwards, fibers are classified in
different qualities according to their thinness and length,
and prepared for the actual spinning process, thus being
subject to gillings -machines that by twisting and stretching,
produce an appropriate wick that will later be introduced into
the spinning machine. Once in the coils, threads are freed
from their imperfections. According to their use, single or
two-ply yarns can be obtained, the latter being coupled and
twisted among themselves in order to be eventually sent,
together with the single yarns, to the weaving section.
Weaving
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process
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The following stage in the production process is weaving,
which consists of transforming yarns into fabrics. This
process is basically divided in three operations: warping,
drawing in and weaving. Pieces are inspected in the looms in
order to correct any faults on the loom before initiating the
finishing operations.
Finishing
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finishing operations are carried out in the wet dyeing
and finishing sectors and they supplement the
manufacturing processes by providing color and texture
to the products. Fibers are colored at the dyeing
section. Paylana counts with nearly all the existing
dyeing systems: in tops, cones, hanks and pieces.
Finishing is one of the tasks that encloses the greatest
secrets of the wool textile industry and it consists of
transferring an adequate dimensional stability and
handle to the weaves. It is divided in wet and dry
processes; among the wet processes there are the
scouring -cleansing of fabrics-, milling -felting-,
setting and centrifuging processes. Once inspected and
classified, fabrics undergo the dry processes of
ironing, decatizing and vaporization, in order to be
finally subject to the last Quality Control processes.
New machines have been incorporated to these sectors in
order to achieve flexibility, speed and new finishing
possibilities, thus seeking to define the product in the
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