Our factory in Östersund

Our Product Philosophy

The foundation of our business model is to create timeless garments with high functionality and quality. Based on that, we have formulated a product strategy for the development of our products.

The garments and products we manufacture:

• Are developed with a clear purpose and the best possible functionality for their intended use. We manufacture products with high quality, where functionality always takes precedence over fashion.

• Our products are made from materials chosen with the aim of providing high durability while minimising environmental impact.

• Our products are manufactured with respect for both the environment and the people who create them. For us, sustainability and responsibility are important in all aspects.

• They are designed and engineered in a way that enables efficient and cost-effective production.

Step 1: Knitting

Around 350 tonnes of merino wool yarn are used each year to produce our garments. The wool is dyed and spun in Europe before being delivered to our factory as finished yarn on cones. The first step in our production process is knitting. In our knitting hall, our unique material, Ullfrotté Original, is knitted using specially designed machines.

A knitting method that maximizes performance

Our unique knitting method is developed to enhance the natural properties of wool and create the most functional garment possible. Precision is required in the machine settings to synchronize the knitting process for Ullfrotté Original. Wool is a living material, and achieving perfect fabrics is no simple task. Issues can sometimes arise that must be handled by our technicians and machine operators. For example, a worn needle may create lines in the fabric, or fibers that are too long may protrude from the yarn and get caught. If this happens, the material is not approved and cannot be used in our products. However, since the material still retains its functionality, we sell it by the meter in our factory store so that creative individuals can make their own garments.

The right humidity for the right result

To ensure the yarn runs smoothly in the machines, a higher level of humidity is required in the air. By introducing steam through the ceiling, we maintain a humidity level of 63–67%, which prevents static electricity during the knitting process. Our technicians and machine operators constantly monitor the production to identify and resolve any issues.

Fewer seams for increased durability

Seams are the weakest points in a fabric and the areas most likely to fail. That is why most of our garments are constructed from circular-knitted tubes, eliminating longitudinal seams. The cuffs for sleeves and legs are also knitted in one piece. Circular knitting also reduces material waste. With fewer seams, the garments are softer and the risk of chafing is minimized.

Sock production around the clock

In our knitting hall, there are also around 40 machines producing socks of various models, around the clock. Our sock machines can knit different patterns directly into the socks. To create a specific design, our technicians program how the needles should move and which yarns should be used in each section.

Steg 2: Preparation

Washing, shaping and cutting

Many people find that wool garments shrink in the wash. We don’t want that to happen at home, which is why we wash all knitted material at 60°C in our factory instead, using only water and nothing else. This process causes the material to shrink by 20–22% and stabilize. It results in a softer, more flexible fabric that is easier to work with. After washing, we tumble dry the fabric, and once the pieces are dry, we shape them using heat and steam on metal forms in our shaping machines.

Meet Clara and Calle

Our shaping machines are named Clara and Calle. Calle shapes all of our body fabric, much like a large mangle, while Clara shapes around 600,000 pairs of legs and sleeves each year using different molds. Some of the molds still in use today date back to when we were called Vinetta and produced nylon stockings more than 50 years ago.

Once the material has been heated and shaped, it must rest for 24 hours before it is time to cut out the pieces that will later be sewn into garments. We strive to utilize as much fabric as possible from each tube. The tubes are layered, with the weight of the material determining how many layers can be stacked in the spreading machine. The length is adjusted depending on the size being produced, all to minimize waste. Each tube is then marked using garment templates. At this stage, the fabric is also inspected once again, and any debris, lines, or other irregularities are marked. The prepared tubes are then moved on to the cutting table.

Cutting dies are like cookie cutters

To achieve clean, straight edges in a soft material like Ullfrotté Original, the entire tube must be cut in one go. To do this, we use cutting dies and a press. The dies vary in shape and size depending on what is being produced. They have a sharp, serrated edge that is placed against the material. The dies are arranged on the fabric like cookie cutters and then pressed through the layers. This process is repeated until the entire tube has been used and the pieces are ready to be sewn into garments.

Fabric waste becomes new products

Even though we optimize production to minimize waste, some leftover material is inevitable. This is compressed into a felt material. From this felt, we produce items such as insoles and seat pads. Making use of leftover material to create new, functional products is both smart and sustainable. We also sell the felt material so that you can create your own products.

Feel free to share your creations on social media using the hashtag #woolpowerDIY. We love seeing how our material is used, and by sharing, we can all inspire each other to create!

Step 3: Sewing

We have a total of sixteen sewing lines, and our seamstresses are divided into teams working on different products. Some sew jackets and vests, while others focus on accessories, Long Johns, or Zip Turtlenecks. No one here works on piece rates, and quality always comes before quantity. If a seamstress discovers an issue in the process, production is stopped to resolve it.

A different model from the traditional factory

In a traditional textile factory, each machine is operated by a seamstress who repeatedly sews the same seam or detail before passing the garment on to the next person, who adds another seam. This often results in a very monotonous and stressful working environment.

At Woolpower, we turn this model upside down.

The same seamstress sews the entire garment

The seamstress moves between machines and, with the support of the quality standards we have established in the factory, acts as her own quality inspector. Moving between machines also creates a better working environment, as it introduces more natural variation in the work.

This means that one and the same seamstress sews the entire garment, from the first stitch to the last.

A name that stands for quality

Once the garment is completed, it is inspected, and if the seamstress approves it, she signs it with her own name. The name label you find in all our garments is therefore both a mark of quality and a way for our customers to understand that there is a real person behind each product, someone with deep knowledge of their craft.

Nothing goes to waste unnecessarily

If a defect is discovered, the seamstress simply removes her name label, and the garment is sold as a second-quality item in our factory store at a reduced price, all to avoid unnecessary waste of materials.

Step 4: Packing and Warehouse

Once the seamstress has inspected and approved her garments, they move on to be packed. All our products are shipped in cardboard packaging, which is folded on-site and labeled with the correct information.

For the past 20 years, we have had a valued collaboration with Daglig verksamhet (daily activity services). They are responsible for packing our accessories, such as beanies and wrist warmers, before they are sent on to the warehouse.

The final step in our production chain is our warehouse. This is where all our products are stored before being shipped to our customers around the world.