Warren Mills is located in the center of Stafford Springs, a small town in the corner of northeastern CT. It was originally settled in 1719 by settlers devoted to cultivation of their land.
By 1765, the town was famous for its natural mineral springs. After the Revolution, visitors came from all over the world to drink the iron and sulphur waters.
Founded in 1853, Warren Mills would go on to become America’s most prominent manufacturer of fine camel hair and cashmere woolen fabrics.
Founded in 1899 in Lawrence Massachusetts, American Woolen Company was the world’s largest wool fabric manufacturer in the early part of the 20th century.
In 1988, famed Italian luxury goods group, Loro Piana, purchased the mill and invested a considerable amount of money to expand and upgrade its facilities, effectively creating America’s only premium quality wool mill.
In 2014, the new American Woolen Company purchased the historic Warren Mills, the only remaining U.S. mill capable of producing the highest qualities of both worsted and woolen cloth.
In 2017, American Woolen Company launched its first luxury garment collection with a commitment to preserving the craft and defining an authentic American style.
|Step 01||Fiber Dyeing|
|Step 09||Greige Mending|
|Step 11||Fine Mending|
|Step 12||Final Control|
|Step 13||Cut & Sew Garments|
We start by dyeing the raw fiber to the desired shade which is the superior way to achieve lasting color. We then blend the fibers to achieve the desired content such as 100% wool, 90/10 wool/cashmere, or any other combination. We then move to carding where we reduce the thickness of the wool fiber to make a fine roving suitable for spinning into yarn. During the spinning process, we draw that roving out to about 20 times its original length and then twist it to make yarn strong enough for weaving. Last, we transfer the yarn onto large cones and ensure that it is perfect before proceeding to the next process.
Through the highly skilled process of Dressing/Warping, yarns are organized in a very specific order on a large dressing creel. Next is the Drawing-In process where the warp beam is prepared for the loom by manually drawing it in the frame to control the weave pattern. Now weaving, where woven fabrics are formed by the interlacing of warp yarns which are set length ways on the machine, and weft yarns are inserted, usually at right angles, to the warp. Finally, fabrics are sent to Greige Mending, an important step in quality control, wheree impurities are removed by hand from the raw, unfinished, woven fabric.
We begin the finishing process by transforming the cloth into a useable material. Both a science and an art, it is up to a highly skilled technician using a combination of 12 different processes involving heat, steam, chemical and water treatments to bring the cloth to life. Next we move on to fine mending where we analyze the fabric inch by inch and remove minor flaws and impurities that were not visible prior to finishing. Final Control is the last step before leaving the mill. Every yard of fabric is meticulously inspected four times before it is packaged for shipping. From here the final samples are put into production for the consumer market.