Cellular blankets have been the baby blanket choice for generations. The small holes in the weave allow airflow, while at the same time trapping pockets of warm air for warmth. This makes them breathable and allows for good regulation of temperature. Cotton, being hypoallergenic and soft, is the perfect fibre for these. Babies also love the soft and shiny satin trim.
In 2016 we started a journey to make our own premium cellular baby blankets. The once-thriving UK blanket manufacturers had all but disappeared, and imports were all that was available. We partnered with one of the few remaining UK weavers and purchased new machinery for their looms, developed special organic cotton yarns to get the material just right, and invented our own methods to sew the blankets in-house. Like our Glovesheets, we manufacture these for our own brand and several premium retailers in different colour combinations and sizes, in-house in Dormansland.
Super Blanket – The truly sustainable cellular blanket
Our buying choices now will affect the future of the planet for our children, so we need to ensure the planet’s precious resources are not wasted and are instead used for quality goods.
The “Super Blanket” is a perfect example of circular manufacturing. Every factory creates waste materials, and whilst we try not to waste any precious cotton, some pieces are too small to use, so we have partnered with a regenerative spinning mill to turn our clean, sorted waste clippings into new upcycled yarn for cellular blankets.
Pallets of white cotton off-cuts ready for recycling. By reprocessing this waste instead of growing new cotton, we estimate these 6 pallets saved 26 million litres of water that would usually be used in irrigation and processing (calculation based on data from the water footprint network).
This yarn is woven for us in exactly the same looms as our Organic blankets to produce a beautifully soft cellular material.
At the end of its circular journey, the woven material returns to our Dormansland factory for final manufacturing. We cut, sew, and pack them here. The finishing touch is the satin trim, which uses baby-safe recycled polyester, made from recycled post-consumer plastic such as water bottles.
As with all DK products, Super Blankets are designed to last. A robust product that doesn’t need replacing has less environmental impact and saves the consumer money in the long term as well!
We have used minimal simple packaging to protect the blanket. The polybags used are made from 30% recycled plastic. So far polybags are the best option to protect the blanket in transit, so that it doesn’t get damaged or wasted. We wouldn’t want blankets discarded. There is always room for further improvement… we are working on it..