Crescent Woolen Mills converts natural and synthetic fibers into spun yarn on the woolen system in its 98,000 square foot manufacturing space. The quality of raw fibers is inspected and the spinning process is controlled and monitored under one roof, using state-of-the-art equipment from around the world.

Woolen System Spinning

The woolen spinning system involves six distinct processes to convert fiber into yarn:

Woolen System Spinning - Blending


This is a process where different fibers are put together to form an intimate blend of different types of fiber in one yarn such as wool/nylon, wool/silk, wool/alpaca, alpaca/angora, etc.

Woolen System Spinning - Carding


This process opens the fiber in a “carding” process and causes the fibers to align themselves in a parallel fashion. Carding determines the alignment of the fibers and also the weight (or thickness) of the yarn. The weight of yarns spun at Crescent Woolen Mills is computer-regulated to continually monitor the amount of fiber entering the machine. The end-product of the carding process is called roving. The roving is then wound onto spools.

Woolen System Spinning - Spinning


Wound spools of roving are taken to the spinning frames and a primary “twist” is put into the roving to give it strength. The degree of twist is expressed in twists per inch. Both the speed of the spinning process and twists per inch are established and then maintained and monitored continuously throughout the process. The end-product coming off the spinning frame is yarn and is wound on a bobbin.

Woolen System Spinning - Winding


In the winding department, all yarn is transferred from bobbins to cardboard cones. During this transfer, if there are any imperfections or thick or thin spots in the yarn, the computer-controlled automated clearers cut out the problem area and the yarn is then air-spliced back together. This insures a uniform consistency to the yarn Crescent Woolen Mills spins. The air-splicing technique and the elimination of knots greatly improves the knitting and weaving productivity as the yarn moves much more efficiently through those processes. From here, single-ply yarn is packaged and shipped to the knitter or weaver.

Woolen System Spinning - Doubling


If the yarn is to be more than a single strand or ply, it goes from winding to doubling. Here the single strand is plied together on tubes, per the customer’s orders, with one or more strands of yarn in a parallel fashion. Crescent’s system can accommodate plying up to four strands of yarn. Different types of yarn can be plied together (i.e. two cotton yarns and one wool yarn, or two wool yarns and two nylon yarns etc.)

Woolen System Spinning - Twisting


The tubes of plied yarns are then placed on a twister which puts a secondary twist into the parallel, plied yarns. This twist is computer regulated. Twist is expressed in “twists per inch.” The yarn then goes from the doubling tubes onto cardboard cones, and is packaged for shipping to knitters and weavers.