Once in Italy, wool undergoes a transformation by way of small, complex operations that call for specialised skills. As a result, the natural raw material gives life to products of rare refinement, the result of the highest textile culture.
The wool mill entrusts the combing to a series of partner firms: the fibres are washed to avoid impurities and combed in order to create the “tops,” the soft wool ribbons intended for local dyers or sent directly to Zignone’s spinning mills. The Spaider factory is the main one: here, spinning takes place at fast speeds with the latest machinery for prepping and roving. In these processes the wool fibres are aligned, eliminating irregularities, increasingly thinning their dimensions and finally preparing the ribbon to be spun. Everything operates around an automated warehouse.
The “roving” is obtained from the finishers and then becomes for all intents and purposes yarn. Steamed, the yarn passes to the winding, where it undergoes ringing that makes it more resistant and gives different qualities depending on the method. The yarn on bobbins can be used as is and inserted as a weft thread during weaving. Or it can be twisted on itself or with other threads in the twisting phase to be then inserted as a warp. Lastly, the crimping and shrinkage phases, managed in a completely automated manner, precede the weaving.

Weaving is the moment of enchantment and technical precision when a fabric comes to life. The warp and weft are intertwined with each other to give rise to the weaves – the union of horizontal and vertical threads – that vary according to the desired design.
Zignone handles all production inside its own facility. For weaving, the wool mill uses the latest generation looms, which rely on air flow to insert the weft threads instead of the traditional mechanical movements. Specialised workers then take care of quality control, eliminating residual impurities and perfecting the fabrics by hand via a process of darning and pre-finishing. In the case of fabrics still to be dyed, the fabrics proceed to the automated machines in the dyeing department. It is the moment of finishing, when the raw fabric finally obtains its distinctive qualities to the eye and touch – the appearance and the “hand” – according to the end use. Finishing is the most important phase of the entire production process, where precision is the priority to achieve the pleasure and comfort we are looking for in a piece of clothing. By managing all the treatments in-house, it allows Zignone to guarantee the highest standards even in the most advanced finishings.