Plastic bottles are sourced from recycling centers and waste management facilities and are carefully examined by trained personnel and/or automated systems to eliminate contaminants and non-recyclable items (i.e. bottle caps) are removed.

The plastic bottles undergo a thorough cleaning and sterilisation process to remove any contamination. After cleaning, the bottles are subjected to shredding, where they are transformed into small chips or flakes.

Next, we use controlled temperatures to melt the flakes into a molten plastic which is then passed through a extrusion tool, shaping the molten plastic into long strands, known as filaments. Follow this is a process called Drawing, which involves stretching these filaments into a fine fibre, commonly known as microfibre.

Next the microfibre is processed through a specialised machine that ‘crimps and cuts’ the fibre. This introduces waves or bends into the fibre which adds volume and resilience to the fibres, ensuring they can provide adequate loft and support when used as fill.

The crimped fibres are loosened then fed into a carding machine which aligns the fibres into parallel arrangements, removing tangles and irregularities. The fibres are now processed to form a thin and continuous web or mat. Once the web is formed, it is compressed and consolidated to increase its thickness.

Now the web/mat is trimmed to the correct size and weight with the amount of fibre used determining the loft and firmness. The outer top and bottom fabric layer is added, then the complete item is sent for quilting.

Following quilting, binding is added to the edges of the outer fabric, to enclose the edges and finish the item. Labeling adds the finishing touches: Quilts have varying labels attached to identify the brand, size, care instructions etc.

The finished item is now subjected to rigorous quality control checks to ensure it warrants the DreamGreen brand. Areas such as stitching, seam quality, size and filling are inspected, and once approved, the product is compressed and vacuum sealed, ready for international transport.