In the Winter 2016 issue of the beautiful home book, Milieu, Josh Needleman shares the process of crafting our luxurious products from pure cotton into art.
A Cotton Tale
Peacock Alley has perfected the ancient process of making bed and bath linens from pure cotton into an art form.
Written by David Masello
Images Courtesy of Peacock Alley
How we sleep depends on what we grow. What begins as puffs of raw white cotton growing on shrubs can be transformed into the luxurious sheets and blankets, soft towels, and plush pillows that bring us daily comfort. When Josh Needleman, who heads Peacock Alley, along with his brother, Jason, visits the textile mills his company operates in his hometown of Dallas, as well as in Portugal, and Italy, he understands the complex process of turning those cotton bulbs into finished goods. "At every step, there has to be a close inspection," Needleman insists, "for this is critical to maintain quality."
The moment newly picked cotton arrives in a facility, the material is carefully scrutinized for irregularities in the bulbs, for knots, for shards of seeds and stems. After carding, a process in which the knotted raw fibers of cotton are smoothed, the cotton is sent to the "blow room," where a thorough final cleaning occurs before the intermingling of different types of fibers, such as cotton and linen, can begin. Huge bales are weighed and apportioned for the goods to be fashion from them. From there, the cotton is palletized, or spun into spools, so that it can be more easily transported and fed into looms. Eventually, during a confectioning process, rolled yardage is cut and sewn to spec for a specific products.
Read more below.