Step 1 – Cutting
First things first, to make a duvet cover we must first cut the fabric from its roll. Our Egyptian Cotton is carefully stored in our warehouse and taken out when we put designs in production. There will be different sizes for each items so whether making a pillow sham or a duvet cover the fabric is measured to match the exact size needed. The fabric is cut flawlessly by our cutting machine, this piece of equipment basically a giant table with an electric blade fitted onto it. This device will slice with precision the fabric without any diversion from its path. At the end of this stage, the fabric is nothing but a square or in the case of a duvet cover a rectangle that is soon to become a part of the set.
Step 2 – Mapping
Now that the fabric is cut in the right shape, our artisans will now map out the design onto the piece of fabric with the help of chalk, tracing paper and a ruler. Using transparent tracing paper, the Dragonfly will be subtly sketched onto the fabric to create a clear outline at the correct spot on the duvet cover. In other words, they will draw a kind of map onto the fabric so that the embroiderers know where to embroider the dragonfly. In this stage, craftsmen will also draw with chalk lines so that our seamstresses know where to do their work. This is essential to ensure that the finished product is not askew and that each piece is exactly the same. This stage uses close calculations and exact replica of Catherine’s computerised design. Here is determined the basic framework for each piece of the bed set.
Step 3 – Embroidery
This step is the embellishment stage, where the Dragonfly design will be embroidered onto the fabric. Now that a frame has been established the fabric is given to our embroidery team who will embroider the Dragonfly by hand. This is extremely detailed work and time consuming, one single Dragonfly to be embroidered on a duvet cover can take up to 4 hours. Our king size duvet cover with the Dragonfly design has 11 Dragonflies so you can see the sheer work that goes behind each piece that we make. Using a wooden hoop to stabilise and straighten the fabric the embroiders will secure the piece inside the hoop and then simply with a needle and thread they will make the design come to life. For each design there may be different kinds of stitches required and each requires a specific technique that can only be perfected with years of experience.
Step 4 – Sewing
Once the embellishments made by the embroiderers are done then the fabric goes to the seamstresses. The sewing stage is when the piece of fabric is finally put together to its final form, previously just a rectangle with embroidery this piece of fabric will now be turned into a duvet cover. The seamstress will use her sewing machine and her vigilant hands to hem the fabric at its edges to make into a case with one side left open where the duvet inserts can be enclosed. This artisan will also sew the labels and washing tags onto the side. The final touch of this is sewing our signature mother of pearl buttons by hand to enable customers to close the duvet cover neatly and beautifully. To sew together a duvet cover and add the tags and buttons it takes our seamstresses approximately 2 hours and a half, with years of practice our seamstresses deft hands work quickly and efficiently.
Step 5 – Washing & Ironing
The washing and ironing stage is a pretty simple but important process, as the Dragonfly duvet cover is now completed it is sent to our washing machines. The duvet cover is washed at a low temperature using a soft detergent and dried naturally. It is then sent to our ironing tables where the products are ironed out entirely to be without any wrinkles. We do these two processes so that when a customer purchases the duvet cover they may unwrap it and put it on their bed straight away ready to use without having to do anything to it.
Step 6 – Packaging
Lastly, we have arrived to the final stage. The duvet cover has gone through cutting, measuring, embroidery, sewing, washing and ironing and is now ready to be packaged. Our last step is effortless but nonetheless vital to us. The duvet cover is folded expertly and placed in our sleek matte white paper boxes. The duvet cover is enclosed in its packaging ready to be delivered to our stores. Our craftsman ensure that the design is seen through the see-through window of the box so that customers can easily and leisurely view the design and colour.
After & In Between Every Single Step – Quality Control
Quality Control is one step that is not numbered simply because it is present at every single step. We have put in place a system to maintain our standards of manufacturing by carefully inserting a checking process at all the stages. A quality control manager and their team are there to supervise that all the processes are carried out following the exact specifications. The quality control is not only done at the very end but at every step of the way, this saves time and extra work. For instance, if the mapping out stage has not been done correctly then it must be redone from scratch, this way the time of our artisans and fabric is not wasted by being embroidered on. At any point if the product is deficient, the quality control team will intervene to correct the problem or redo from the beginning.
This entity reviews quality at the highest level and will be ruthlessly conscientious. These expert ensure that all the criteria are met ensuring that the end product is perfection.