It all starts either in one of MADALO’s chatter groups or in MADALO’s office in Münster. There the design of the new wraps; colors, gradients, weaves, weft and warp varieties, are determined by either the customers of MADALO or Yuridia and Christoph.
Once the design is finalized, the necessary cotton is purchased. MADALO exclusively uses OEKO-TEX® 100 for its wraps, which -around the world- is certified for babies as Class 1 combed cotton, which is known for its exceptional purity, stability and softness, thus allowing a great comfort.
The cotton is then delivered to Juan and Jose’s weaving mill where the weaving can soon begin!
First, however, nearly 1,000 warp threads (these are the cotton threads which run in the longitudinal direction of the sling), calculated by MADALO in Münster, Germany in accordance with the desired colors and gradients, need to be arranged.
Subsequently, the almost 1,000 threads are successively wound around the warping frame by Juan. To do this, Juan holds groups of threads based on the color graduation in one hand, while with the other hand he turns the warping frame around itself. Depending on the total number of colors and the subtlety of the color graduation this is done approximately 5,000 times! This work is extremely complex and requires very high concentration. Depending on the number of colors and subtlety of the color graduation, for this part of the weaving Juan needs 2 - 6 days.
After that, again by hand, the threads are unwrapped from the warping frame and stored in the correct order -corresponding to the colors used in the wrap- like a big ball of yarn or a long braid, in a temporary container for storage. At this point it is crucial to ensure the threads do not get tangled! Subsequently, the "cotton-braid" is connected and threaded through the nails on a beam fixed to the middle of the warp beam, which nails are used to sort and fixate the threads. Three people are needed to wind up the almost 1,000 cotton threads onto the warp beam: two people turn the warp beam and the third keeps tension on the "cotton-braid" until the entirety of all threads are wound around the warp beam.
After this, the threads are then individually connected with the warp threads of the previously woven wrap, in the correct color sequence, by knotting each thread, and can then be threaded into the shafts of the loom. For this step of the weaving process concentration, good eyesight and endurance are definitely needed, because the threading lasts about 2 days!
After the warp threads, the weaving shuttle –which during weaving shoots the weft threads between the warp threads on the loom- can be prepared. To do this, the individual threads are spun by hand onto the spools by means of a bicycle rim.
And finally the weaving can begin :)
To give you an idea: in a 5 meter long wrap, each weft thread is shot between the warp threads 4,500 times. By simultaneously working the foot pedals, the weave –e.g. diamond twill weave or herringbone twill weave, is set.
With patience and love the entire warp beam is woven so that a very long piece of fabric is formed.
This fabric is then packed and shipped to Germany, where it is cut and seamed into a MADALO baby wrap.
Once ready and carefully packed there is only one more thing missing: the wrap awaits you to continue its story!
MADALO – handwoven stories!