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Our bamboo is grown without fertilisers or pesticides and no irrigation, only rain water. First, the green shoots are cut into chunks of raw bamboo.
Next, the bamboo is soaked in a solution to soften it. The system is closed loop - all liquid is recycled and all solvents are captured and removed to ensure that the process is as eco-friendly as the bamboo itself.
The dehydration process allows us to extract the bamboo pulp that is then dried into flat sheets.
When the bamboo sheets are completely dry, they are ground into a soft, feathery material.
The soft, feathery material is then extruded and spun into a viscose yarn that we use to knit our garments. The garments are knitted in tubes resulting in very little fabric wastage compared to traditional cut and sew garment manufacturing which wastes up to 20% more fabric (excludes our t-shirts and baby garments which are cut and sew).
Lyocell fiber is produced from dissolving pulp, which contains cellulose in high purity with little hemicellulose and no lignin. The Bamboo stems are chipped into squares about the size of postage stamps.
The chips are digested chemically to remove the lignin and hemicellulose. At the lyocell mill, rolls of pulp are broken into one-inch squares and dissolved in N-methylmorpholine N-oxide (NMMO), biodegrades without producing harmful products, giving a solution called "dope".
The filtered cellulose solution is then pumped through spinnerets. The spinneret is pierced with small holes rather like a showerhead; when the solution is forced through it, continuous strands of filament come out. The fibres are drawn in air to align the cellulose molecules, giving the lyocell fibres its characteristic high strength.
The fibres are then immersed into a water bath, where desolvation of the cellulose sets the fibre strands. The bath contains some dilute amine oxide in a steady state concentration. Then the fibres are washed with de-mineralised water.
Next, the lyocell fibre passes to a drying area, where the water is evaporated from it. The strands pass to a finishing area, where a lubricant is applied. This step is basically a detangler, prior to carding and spinning into yarn. At this stage, the dried, finished fibres are in a form called tow, a large untwisted bundle of continuous lengths of filament. The bundles of tow are taken to a crimper, a machine that compresses the fibre, giving it texture and bulk. The crimped fibre is carded by mechanical carders, which perform an action like combing, to separate and order the strands. The carded strands are cut and baled for shipment to a fabric mill.
Our cotton is grown without fertilisers or pesticides and no irrigation, only rain water.
Raw seed cotton must cleaned and free of debris. Seeds, burrs, dirt, stems and leaf material are removed from the cotton during a process called ginning.
Once free from debris, the cotton goes to the gin stand where circular saws with small, sharp teeth pluck the fibre from the seed. This process makes the sliver smoother so more uniform yarns can be produced. Then the cotton is packed tightly into bales, ready to be processed into textiles.
Even though the cotton is cleaned during the ginning process, it's not nearly as clean as it needs to be. Cotton fibres are shaved from the bales and sent through a series of cleaning and drying machines. The mixed and fluffed-up cotton goes into a carding machine which finishes the cleaning and straightening of the fibres, making them into a soft, untwisted rope called a sliver (pronounced sly-ver).
On modern spinning frames, yarn is made directly from the sliver. The spinning devices take fibres from the sliver and rotate it up to 2,500 revolutions in a twist that makes fibres into a yarn for weaving or knitting into fabrics.
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