Custom Fiber Processing
For Farmers
Why choose Battenkill Fibers for your custom fiber processing?
A wealth of expertise and experience.
At Battenkill, our community is made up of people who truly appreciate wool–so our staff needs to be, too. Many of our staff are also spinners, weavers, knitters, dyers and fiber crafters, and we know the importance of consistent yardage, skein weights, plying and appearance. Our team leads are well-versed in how to run different types of fiber through production, and our mill has gained a reputation for excellence in working with heritage and rare breed wools over our 14 years in operation. This distinction makes us one of the top choices for fiber farmers and ranchers in the Northeast and beyond.
Your fiber back, regardless of your order size.
You’ve put in the hard work of caring for your fiber animal: shearing, sorting, storing and delivering your fleeces to the mill, and we look to honor that commitment through our production process. When you work with Battenkill Fibers, you know with certainty that the yarn or roving returned to you is your own fiber. We will also let you know if fiber you bring us is not suitable for processing.
A smoother, longer-wearing product.
Our semi-worsted machinery is especially good for processing long-wools, mohair and alpaca. We can make even traditionally “scratchy” fibers feel luxurious next to your skin. We can also run medium and fine wools provided that the staple length is at least 3”. Regardless of breed, our pin-drafter based semi-worsted process makes yarn uniform and aligns the fibers in the yarn so that they lie parallel to one another. The yarn is loftier and the twist is well-balanced, creating crisp stitch definition in knitted fabrics and a premium finished product.
Local, personalized service.
Drop off your fiber and pick it up in person–just call ahead for an appointment! Want to see how your fiber will be processed? Schedule a mill tour and get a personalized walkthrough of our facility. Call ahead or email us at battenkillfibers@gmail.com to make an appointment.
Community investment.
By entrusting us with your fiber, you are making an important contribution to sustaining our region’s rural economy. We are doing our part to keep New York State’s value-added agricultural economy moving! The people who work at Battenkill Fibers are local folks, many of them fiber farmers. We live here, and we care about the future of our place on the land. We draw the least amount of water and power possible in our production process, and dispose of our waste in an environmentally responsible manner.
For Brands
Looking for a curated fiber blend?
Let us guide you through making your dream yarn.
Indie dyers, yarn store owners, knitting guild members and designers: if you’re searching for a signature product or special project, come to us! Our team is ready to help you design your dream yarn or finished product from scratch, walking you step by step through each part of the process. New to yarn? We’re happy to help you learn more along the way.
Superior wool sourcing.
Looking for something unusual, special or rare? Hoping to create a unique fiber blend perfect for a particular use? We’ve seen it all–and what we haven’t seen, we’re ready to tackle. Our extensive network allows us to source exactly what you’re looking for, and make recommendations you may not previously have considered.
Regional partnerships.
Our specialty is processing fiber and spinning yarn, but we’re always ready to help you anticipate and navigate the next steps in the production process. At Battenkill, we can take your project beyond our mill to add color through natural or commercial dye methods, be woven into bespoke textiles or even knitted into beautiful finished garments. We’ve developed connections with trusted dye houses, knitting mills and local weavers–and we can help you navigate your project through every step.
Transparent production.
It’s more important than ever to be knowledgeable about where your materials come from, and consumers are looking for brands with values that align with their own. At Battenkill Fibers, we support a more transparent supply chain and align ourselves with other companies and fiber sources that share our commitments to the environment, domestic production, animal welfare and labor rights.
Our Custom Processing Steps
Yarn processing starts with our people
Battenkill Fibers’ knowledgeable staff care about the quality of your finished products. We are committed to our work; and relate to our clients because most of us are also farmers and raise fiber animals of our own.
Skirting – Nothing is more important than the quality of fleeces. Please carefully remove dung tags and vegetable matter from your fleeces before sending them to us for processing. If we need to skirt your fleece before processing, it will add time and expense to your order. If you have any questions about your fleeces or how to skirt it please call us for a consultation. You may want to mail a sample for us to evaluate before sending in your entire job. Our Skirting Guide may be found here. Our minimum fiber length is 3”, and minimum order is 10 lbs.
Scouring – We begin the simple yet important washing process on all skirted fleeces by using very hot (170 degrees) water and a specially-formulated (and environmentally-safe) soap to emulsify the lanolin in the fiber. There are two washes and three rinses. The fiber MUST be free of lanolin and not feel tacky because it will gum up our machines. We reserve the right to determine if a fleece is clean enough and will wash it again if we need to. Fine fleeces require more washes, as do really dirty fleeces. Next the water is extracted from the fiber and the washed locks are air-dried overnight on a rack system. Note: We never use harsh, abrasive chemicals in our scouring. Nor do we use acid baths to remove vegetation or add bleach to enhance our whites.
Picking – Some fiber will be sent through our picker to open up the staple and shake out the dirt and chaff. We add a natural anti-static oil sometimes to aid in the processing.
Carding – Battenkill Fibers uses an 84 inch Davis and Furber carder. We completely refurbished it including all new carding cloth on the workers and strippers in 2022. This machine opens up the fibers and teases the clumps as they go over the cylinders and rollers, called workers and strippers. A wide blanket of batting, called a web, spills out the end of the machine and is condensed to 16″ before being fed into the coiler, producing 8 inch-wide roving.
Pin drafting/combing – Our three Warner-Swassey pin drafters are very important machines. They make uniform sliver ready for spinning (by our machines or by hand-spinners) by straightening the fibers and aligning them parallel to each other, all in one direction. This makes a softer, bouncier roving and yarn.
Spinning/plying – Battenkill Fibers runs a 60-spindle Gaudino spinning frame and a 108-spindle Gaudino. Each spinner is capable of spinning a wide variety of yarn weights and twists. Our Meadows twister can make two, three, or four-ply yarn to suit the various needs of hand-knitters, knitting machines and weavers.
Skein winding – Our standard put-up is in 3.5 oz (100g) or 4 oz. skeins. Other sizes are available, as is optional cone-winding.
Additional Services
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A representative of Battenkill Fibers is available to guide dye services for your product from beginning to end with one of our dye house partners.
Dyed in the Wool with Acid Dyes
After washing your fiber and before carding it, have us dye a portion to achieve evenly-distributed color across your entire dye lot. 10 lb. minimum per color.
Kettle Dyeing with Acid Dyes
Our in-house team will dye your yarn for you after it is spun and skein wound here at the mill. 3 lb. minimum per color.
Or we can send skeins of your yarn off to our partners Caledonian Dye Works in Philadelphia. Our team arranges shipment to and from the dye house, coordinates the dye job including color development and sampling, and does a final quality assurance check when your yarn returns from the dye house. Yarn can be returned to you on cones for weaving and machine knitting or on skeins for hand knitting. 30 lb. minimum per color.
Speckles and Handpaints with Acid Dyes
Develop colors that are uniquely your own, inspired by photographs or created from your own imagination. Schedule a Color Palette Development session and we’ll arrange these special, one-of-a-kind applications with one of our artisan partners local to your region, or with our in-house dye team. 3 lb. minimum per color.
Kettle Dyeing with Natural Dyes
Natural dyeing is having a resurgence, with many customers requesting and seeking out textiles dyed with botanical extracts and materials. These colors are unique season to season and are developed in collaboration with our friends at several different natural dye companies. A member of our team will guide you step by step through the process of developing your colorways and coordinating the process, with a final quality assurance check when your yarn returns. 10 lb. minimum per color.
Solid Dyeing with Acid Dyes
Looking for a truly solid finish? We work with Caledonian Dye Works to have your yarn tube-dyed for the most even, professional finish available on your yarn. This is a top choice for heathered fibers. Yarn can be returned to you on cones for weaving and machine knitting or on skeins for hand knitting. 30 lbs minimum per color
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Are you ready to take your yarn one step further and create a beautiful finished woven or knitted product you can sell? We’re excited about helping you make the choice to support domestically and locally produced goods.
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Learn how to properly clean and prepare your fleece for spinning.