SUNRISE WOOLEN MILLS

BACKGROUND STORY

The story of how a world-class wool blanket is made

BasShu has been producing wool blankets since 2012.
In 2018, a new tag, "SUNRISE WOOLEN MILLS," was added next to the brand's name tag. This tag represents Hinode Keori Co., Ltd., which continues to weave BasShu's wool blankets. Rather than simply stating "Made in Japan," the name of a specific weaving mill in Izumiotsu City, Osaka Prefecture—a proudly Japanese wool textile industrial area—was inscribed. This new endeavor aims to properly convey who makes these special items and how they are made.

The "SUNRISE WOOLEN MILLS" tag
The creation of a BasShu wool blanket involves many hands from factories and artisans in and around Izumiotsu. The story of this division of labor begins at a dyeing factory in Izumisano, not far from Izumiotsu.


"Dyeing factory in Izumisano City"
Here, wool yarn is first dyed to the ideal color. Dyes formulated in the lab based on detailed data are placed into large vats, and the yarn is immersed for dyeing. Even before this step, delicate consideration is required.


The first process is "re-winding."
This involves re-winding the yarn as it arrives at the factory, taking into account indoor humidity and individual differences in the wool, to ensure the dye penetrates evenly. Compared to other natural fibers, wool from different parts of a sheep's body behaves entirely differently, requiring the correct tension for each type of yarn.


"Re-winding process"
The re-wound yarn, processed with artisan skill, is then dyed in large vats, again with appropriate consideration for the wool's specific temperature and time requirements. The work constantly explores ways to maintain the wool's soft and fluffy texture, in addition to achieving a beautiful, rich color. It's no exaggeration to say that this dyeing and subsequent drying process largely determines the blanket's final texture and feel.


And then, it's the turn of SUNRISE WOOLEN MILLS = Hinode Keori Co., Ltd.
At this weaving mill, the blankets are woven. There are eight looms in the factory. However, only one of them weaves BasShu's wool blankets. This machine, in continuous use since the factory's inception, is over 50 years old and was made by a now-defunct manufacturer.


As a result, there are no longer specialized repairers, and new replacement parts cannot be acquired. This loom, which could stop at any time, must be repaired by the mill's own artisans when it breaks down. However, that very loom is the mill's most valuable asset. The artisans diligently listen to the sounds the machine makes each day, striving not to miss the slightest irregularity.


Artisans of Hinode Keori
The jacquard woven by machines, deeply cherished by the artisans, produces 20 meters per day. This equates to only about 10 blankets. The rarity of the loom and its production volume highlight the high value of woven blankets.


The woven fabric then goes to Izumiotsu's only napping factory. To achieve a more beautiful nap, the fabric is first moistened with water. Then, the fabric passes through a machine equipped with many fine needles to raise the nap of the wool.


The artisans constantly monitor the machine, considering humidity, temperature, weave condition, and even the machine's "mood," to determine how many times to pass it through the rollers. The nap is gradually raised through the artisans' intuition, creating the exquisite texture that BasShu desires. After careful drying, the blanket is finished with a blanket stitch. This is how BasShu's wool blankets are created, through the accumulated precise judgments based on the artisans' intuition at each step of the process.


The high skill of the artisans, their strong love for their machines and quality,
One such product, condensing various elements that Japan can be proud of, is surely unobtainable elsewhere.