The carpet connection
Supplying wool to NZ's pure wool carpet maker
It takes quality wool to make a quality Cavalier Bremworth carpet. It's one of the key reasons that Cavalier Corporation owns Elco Direct and has a 50% stake in the largest, most efficient wool scour operation in the world.
More than 90 percent of Cavalier Bremworth residential carpets are graded extra heavy duty, providing a significant point of difference in terms of quality and durability from others in the market. All Cavalier Bremworth carpet is designed and made entirely in New Zealand and well over half of its production is exported to Australia, Asia, the US and UK.
The best type of wool for carpet making is a coarse wool, around 36-40 microns and between 75-100mm long. Lengthy fibres are needed to bind the fibres together and provide strength, while the whiteness of New Zealand wool makes it among the best in the world for dyeing lighter and pastel shades.
Elco Direct's expert team deals directly with growers and has an in-depth knowledge of both the farms and the farmers, often being in the shed at shearing time and advising on correct preparation standards. Much of the wool required for carpet making comes from Romney-cross sheep, prevalent in the North Island.
Buying wool low in vegetable matter is critical when it comes to producing carpet that is clean and clear. Gorse remnants poking through is never a good look (or feel) so when and where the wool is bought is a key factor.
The next step is the wool scour and Cavalier Corporation has a 50% stake in Cavalier Wool Scourers which operates two very modern and large capacity wool scours in Napier and Timaru. Recently, Napier set a new world record scouring more than 280,000 bales - which equates to more than 10 million fleeces!
The wool is then sent to one of Cavalier Corporation's two spinning plants in Wanganui and Napier to be dyed and spun into yarn for production into carpet at the company's tufting plant in Auckland.