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quality chara

arch pillow img
fabric weaving

fabric weaving chara

We start on our fabrics — such as designed fabrics — by selecting the thread that is suited for the application, then knit it into original fabrics that we have developed on our own or jointly with others, and then carry out dyeing processing and value-added processing at our dyeing shop.

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dyeing

dyeing

At our dyeing shop we carry out dyeing processing and value-added processing. Thanks to a state-of-the-art circular knitting machine that we installed a few years ago, we are able to carry out processing that had been difficult with previous technologies.

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assembly

assembly

After all steps in the manufacturing process are completed, the items are subjected to a final examination for any overlooked problems such as defects in the sewing finish or soiling of the fabric, and after the items have been carefully checked one by one, they are packaged.

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cutting sewing

cutting sewing

Fabrics that have passed inspection at the knitting shop are carried to the cutting shop, stacked in multiple layers, and cut. They are then carefully sewn by our craftspeople.

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manufacturing chara

Nemuri Seisakusyo’s arch pillow brings together a large number of techniques and the experience of many craftspeople. Here we pay a visit to a manufacturing site of a kind that one rarely has a chance to see.

Fabric weaving
Every day at our manufacturing plant in Japan, specialists put their reliable skills to work, and our fabric weaving, dyeing, cutting, sewing, and assembly shops work together to bring the individual product to completion. Although a task may be challenging in the beginning, if each person advances step by step with a feeling of pride and responsibility, then both the skills and the feeling that went into them will be carried on and handed down.
fabric weaving
This is our knitting plant in Ashikaga City, Tochigi Prefecture. We start by selecting the thread that is suited for the application, and then knit it into one of the original fabrics that we have developed on our own or jointly with others — such as one of the few warp-knit tricot fabrics in the world that use cotton thread, circular-knit fabrics such as double-width sinker piles and smooth knits, and designed fabrics created on computerized jacquard looms — and then carry out dyeing processing and value-added processing at our dyeing shop. Thanks to a state-of-the-art circular knitting machine that we installed a few years ago, we are able to carry out high-tech jacquard processing of double-faced fabrics precisely and accurately, something that had been difficult to achieve with previous technologies. And at the end, all of our fabrics are finished by hand by our seasoned craftspeople, making for knitted fabrics of high quality.
dyeing

Finished fabrics are carried to the cutting and sewing lines.

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traccing of pattern
cutting sewing
Fabric that has passed inspection at the knitting shop is carried to the cutting shop. After the fabric has been subjected to entry inspection, it is stacked up in multiple layers in preparation for cutting in the manner of a mille-feuille pastry.

A cardboard pattern is used to trace a pattern on the fabric, then the cutting machine cuts the fabric all at once following the pattern. Once the fabric has been cut into the shape of the individual parts, it is carried to the sewing line, where our craftspeople sew the pieces together. After sewing, the pieces are once again subjected to rigorous checking and inspection, and only items that pass inspection are taken to the assembly line.
finishing of sewingh

Finished fabrics are carried to the cutting and sewing lines.

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finishing of sewingh

The cotton is brought to the plant as raw cotton that has been compressed into clumps weighing hundreds of kilograms. The raw cotton is passed through a cotton opener, a machine equipped with rollers fitted with sharp blades that minutely untangle the cotton as it passes through the machine. The cotton used in our arch pillow is “ft” cotton manufactured by TORAY. This cotton features thinner fibers than those found in ordinary polyester cotton, and this causes it to hold a great deal of air, allowing it to be finished into a soft, fluffy form that is almost like down.

cotton

Cotton that is sent through the blower passes through a cotton opener while being conveyed to the blowing nozzle. The cotton is ejected along with the air and blown into the individual parts. The quantity of cotton blown into the parts is adjusted so that the interior of each part is filled uniformly, so that each part ends up with fluffy cushioning properties.

assembly
arch pillow

Completion

After all steps in the manufacturing process are completed, the items are subjected to a final examination. Checking is carried out at each step of the process, but after assembly the items are closely checked again one by one for any overlooked problems such as defects in the sewing finish or soiling of the fabric before being packaged.