How Yarn is Prepared & Packaged

Welcome back to The Crochet Crowd as well as Yarnspirations.com.

Join me today in the making of the Caron One Pound yarn ball proudly made in the

USA, in Washington, North Carolina. Before we can enjoy this leading brand

of yarn, the fibers are died and spun into yarn strands in another location in

the united states... before even coming to the Caron Yarn Factory. They come in

tightly wound spools which require processing before you recognized it as

the Caron One Pound yarn ball.

Now look carefully the spool yarn, it appears to be thin but it needs to be

brought to life before crocheters and knitters can enjoy this yarn. Here

the operators are loading white spools even though red spools are already loaded.

They're actually, in fact, changing the colors of the yarn in mid process to

avoid setting up the machine from scratch.

There are three spools per conveyor and the process is really quick that

each of the three spools are actually tied to each other. When one

spool runs out,

it automatically pulls the next spool without having a machine to stop. The

demand of the yarn by the public is too great for these machines to be stopped

during a shift.

Did you just see that? The operator just grab the spool and the tied the strings

together as she lifted it up to put the new spool underneath. The spools need to

stay in order to prevent tangling. The strand that she is grabbing is the

inside strand of the spool that is tied to the outside strands of the next


If you have a knot inside your ball, chances are that it's the industrial spools

ending from one to the other.

As we move further down the machine you can see other spools are being unwound

and fed into the machine at a super fast speed.

Look carefully... you to see the strands flying up... most likely not. Let me show

you a better view in another machine. You can see it clearer when processing white


Look how fast that is unwinding. Those spools, now that the cones are loaded,

the strands travel up over the aisle and then down onto the processing conveyor.

The machine lays down the yarn in a circular formation onto the conveyor.

The machine is timed to stop and start based on the winding process on the

other side of the line.

The strands need to be brought to life with a heavy blast of steam.

The thin strands will immediately expand... you can see the difference of the yarn

thickness from one side of the steamer to the other.

Now that it's all puffed up, it's going to be slightly damp and needs to be


So the next machine is the machine that winds the yarn into rolling into a yarn

ball once out of the dryer.

The yarn is on a direct course to the final ball winding process due to your

tensions each of the conveyor moves separately to prevent the strands from

moving too fast or too slow to the winder.

The winders have a really wide diameter and it is wound to the yarn spool very


The machine is timed to rotate a set number of times per cycle . Winding tightly

allows the winding process to give an accurate yardage and weight to the yarn


You can see that each one of the conveyors are working independently.

When the winding stops, the conveyor still moves forward to get ready for the

next cycle and stops when the strands are detected at the end of the conveyor,

The operator cannot remove these tightly well balls on their own.

The machine ejects forward and pushes them almost all the way off.

They removed the ball and then set it on the conveyor, while resetting the spool

at the same time to be ready for the next spin cycle.

They work down the line as each one of the winders work togethe. Once the

operator is done, they will begin the winding cycle once again.

Did you notice that the interior of the yarn ball collapsed when it was taken

off the winder? The tightly wound balls have a big diameter so that when it's

removed from the winder,

the yarn relaxes and the tension is released to the inside of the ball.

The yarn ball now resembles a tin can.

It needs one more process to make it look more a yarn ball as you will see it

on the store shelves.

The yarn ball goes through a space of the machine that is too small.

This causes the ball to compress and roll at the same time.

This makes the center of the balls pop outward to give it the classic look of

a yarn ball. The ball is perfectly shaped and ready to be labeled. The automatic

labeler lifts up and secures the ball band around the ball and then moves

it forward down the line.

The yarn ball is now ready to be packaged and heads down the line where

the yarn is put into a bag to protect it during transport and then placed into a box.

The yarn is now sent to the warehouse and when the stores ordered the yarn,

it's now picked, wrapped and ready to ship . It's now ready and waiting for a

truck to bring it to a store near you.

So that's been pretty cool.

Now that you've seen how it's done, let's examine the yarn ball knot as

it's a pet peeve.

So why can there be more than one know in a yarn ball?

It's an established policy within the yarn industry that multiple knots are

acceptable within a yarn ball.

This is done to prevent excessive waste and, honestly, perfectly good yarn from

ending up in a landfill. Higher waste by the manufacturer means that the

finish yarn balls must be higher price and to make up for the cost of materials

labor and handling of yarn that is considered a waste.

Multiple knots get into a ball at the spinning process before its wound to the

final ball. Like you've seen earlier the process of the spinning is extremely

quick and sometimes the fibers break the industrial spools are wound by the weight

and should a strand break, the operator removes the yarn and the Machine continues to

spin this yarn until it hits its target weight.

So while I understand that knots in your ball can be a pet peeve,

We have to remember that the yarns are made up for fibers that are spun

together. To guarantee a ball without knots, will create excessive waist and

will drastically change the retail prices of the yarn to make it

affordable. At the end of the day,

consumers want to be able to afford the yarn and in today's society we need to

cut our waste and be more environmentally conscious.