Our factory

As we all know, good sleep is beneficial to the body, so our factory must be beneficial to you and a great place for you to learn how we get our silk-filled duvet done.
Our factory is not that big enough to hold thousands of workers, but it is a great place with many talented people and we extraordinarily pay more attention to sustainability, which stands out from many other factories.
For us, sustainability is the number one aspect to have in mind. We always want to do our best to make our products as sustainable as possible, all the way from design idea to sampling, production, and freight to our finished products.
We want to create bedding with a timeless design that will never go out of style, in high-quality fabrics that are durable and easily maintained, and as kind as possible to our planet.

Let's check out our process
1
Choose quality cocoons
Cocoon silks are one of most important materials extensively used in textile industry. Keep working on searching for double cocoons, which only account for 13% of all cocoons
Based on the number of silkworms in 1 cocoon, these cocoons can be divided into single cocoons and double cocoons. A single cocoon is a cocoon formed by 1 silkworm; a double cocoon is a cocoon formed by 2 or more silkworms spinning silk floss together. A double cocoon is usually larger in size and more stretchy and fluffy, making it the best choice for making silk duvet.
2
Boil cocoons
During boiling, some amount of water enters the cocoon cavity and makes it soft. This helps in separating the fibres from cocoon during the reeling process. … Due to hot water, pupa dies and does not emerge out of cocoon.
Without boiling cocoon, the strands would be brittle which breaks them into smaller pieces and would make it difficult to spin threads out of the cocoon.
Timing is also the key to boiling cocoons. An experienced artisan can judge by the look and touch to determine when it is the right time. If boiling for too long, it will result in a fragile and weak product, yet not boiling long enough will produce a tougher fiber.
3
Peel cocoons
This step is to unravel silk cocoons from dead silkworms
4
Stretch cocoons into a pocket
Then the cocoons are hand-stretched on a U-shaped wooden rack. In order to maintain the good flexibility of the silk floss, the stretching process must be carried out in water. 4 silk floss can make one pocket, 20 layers overlap and interweave each other.
5
Dehydrate the silk floss pockets
Use a damp machine to remove the moisture from the wet silk bag, and then use nylon thread to string it up and get it under the sun to dry completely. Silk floss reaches its perfect softness when any moisture has been removed.
6
Hand stretch and layer the silk floss sheets
Workers grad the edge of the silk bundle and stretch it wide to match the dimensions of the desired blanket. Layer by layer, the blanket begins to take shape. Once the silk fiber layers are stacked together, a silk duvet is complete.
With the wisdom of our ancestors and the long history of sericulture, Silk-filled duvet really deserves what it costs . At Tunatutu, what we really desire is that everyone will have chance to enjoy what we did and start sleeping better!