Blankets: History, Evolution, and Manufacturing Process

by Eman Abdallah Kamel

Blankets are used worldwide as an essential covering for warmth. In this article, you will learn about the blanket’s history, evolution, and manufacturing.

Introduction

A blanket is a large piece of smooth fabric designed to cover or wrap around most of the body. Its thickness helps retain body heat.

For thousands of years, blankets have been essential to human life, providing warmth, comfort, and protection from cold weather. Yet, their significance extends well beyond mere practical utility. Throughout history, blankets have reflected the cultures, traditions, and lifestyles of various societies, as well as their level of technological development—ranging from the simple animal hides used by early humans to exquisitely and skilfully woven wool blankets.

The leading blanket manufacturers worldwide use advanced production technologies and high-speed machinery to manufacture millions of blankets annually for international markets. Jiangsu Etang Household Products Co., Ltd. specialises in modern manufacturing and customised bedding, while Shandong Green Tiantong New Energy Co., Ltd. focuses on large-scale production of fleece and thermal blankets. Shaoxing Leila Textile Co., Ltd. is known for its polar fleece, coral fleece, and micro-flannel textiles. Standard Textile serves the healthcare and hospitality sectors by supplying commercial-grade blankets and institutional bedding across global markets.

Wool blanket. Culture: Navajo, United States. Image source: metmuseum.org

Blankets and Culture

Beyond their practical purpose, blankets have held cultural, economic, and symbolic importance in many societies. Different communities developed distinctive designs, colours, and weaving techniques that reflected their identities and traditions. For example, the Navajo people of North America became well known for their beautifully woven wool blankets, featuring geometric patterns and strong colours. These textiles were used as clothing, coverings, and valuable trade items. Their designs reflected a combination of traditional weaving practices and cultural influences. (The Metropolitan Museum of Art)

Another famous example is the Hudson’s Bay Point Blanket, which became an important item in the North American fur trade. The Hudson’s Bay Company introduced its distinctive point blankets in 1780. The short lines, known as points, indicated the size of the blanket. These wool blankets became widely traded and were valued for their warmth and durability. However, their history is also connected to the colonial fur trade and its impact on Indigenous communities.

History

History of wool blankets through

1. The Ancient Civilisations

Blankets and other textile coverings played an important role in ancient civilisations. In ancient Egypt, linen was one of the most important textile materials. It was produced from flax fibres and used for clothing, household textiles, and other purposes. The warm climate encouraged the use of lightweight fabrics, although wool and other materials were also known. In ancient Greece and Rome, woollen textiles were commonly used for clothing and household purposes. Wool was valued because it provided warmth and could be woven into different types of fabric. Textiles were also important indicators of social and economic status, as the quality of materials and craftsmanship varied according to wealth and availability. In other regions, communities developed their own textile traditions using locally available materials. These traditions contributed to the development of different weaving patterns, colours, and methods of producing warm coverings.

2. The Middle Ages

During the Middle Ages, blanket production became increasingly important in European households. Wool was one of the most widely used materials because sheep farming was common in many regions. Woollen blankets provided protection against cold weather and were especially useful in homes that had limited heating facilities.

The production process involved several stages, including cleaning the wool, spinning it into yarn, weaving the yarn into fabric, and sometimes applying finishing treatments. These processes were often performed manually by skilled workers. Blankets were valuable household items, and their quality depended on the type of wool, weaving technique, and amount of labour involved. In some communities, textile production also became an important source of income and trade.

3. The Industrial Revolution

The Industrial Revolution, which began in Britain during the eighteenth century, brought major changes to the textile industry. The introduction of mechanical spinning and weaving machines transformed textile manufacturing. Machines made it possible to produce yarn and fabrics more quickly and in larger quantities. This increased production, reduced manufacturing time, and gradually made blankets more accessible to a wider population.

The growth of textile factories also encouraged the development of new manufacturing methods and improved fabric quality. Wool remained an important material.

4. Modern Developments

During the twentieth century, advances in textile technology introduced new materials and manufacturing techniques. In addition to traditional natural fibres such as wool and cotton, manufacturers increasingly used synthetic fibres, including polyester and acrylic. These materials offered several advantages, such as affordability, lightweight construction, easy maintenance, and resistance to certain forms of wear. New manufacturing techniques also allowed blankets to be produced in different textures, thicknesses, colours, and sizes.

Today, blankets come in various forms, including wool, cotton, fleece, electric, and knitted blankets, as well as decorative throws. Some are designed primarily for warmth, while others serve decorative, travel, outdoor, or specialised purposes.

Manufacturing Process

1. Traditional Blanket

Wool Shearing: Sheep are shorn annually between February and June using scissors. Before shearing, they are washed to remove dust and dirt from the fleece. Shearing and fleece sorting are typically conducted in grazing areas.
Carding: The wool carding machine consists of two rollers: a hollow cylinder fitted with a bent metal strip that advances the wool via a conveyor belt, and a spiked carding roller with a coarse pitch, similar to a licker-in, which opens the fibres. Unlike conventional carding machines, it lacks a doffer and coiler trumpet for forming sliver or top. Its primary function is to open the fleece, producing loosely carded wool of relatively coarse quality. The wool is typically carded two to three times to improve fibre separation, then manually carded further by the artisan.
Spinning: Two types of spinning systems are used: the hand spindle and the treadle-operated spinning wheel. Both systems are primitive and are traditionally employed for spinning wool. The yarns produced by these methods are characterised by their coarseness, a high degree of twist, and the presence of protruding fibers.
Weaving: The spun yarn is wound on a special type of wooden frame. The warp sheet is prepared directly from the hank produced on the wooden frame. For making blankets, a primitive loom is used.

Traditional blanket making has a high production cost due to the intensive labour required for spinning and weaving.

Characteristics of Traditional Blankets:

Durability: Produces blankets with long-lasting quality.
Excellent warmth: Provides good insulation and warmth.
Rough initial texture: Blankets initially feel rough and harsh to the touch.
Improves with use: Becomes softer and more attractive after repeated use.

2. Modern Blankets

Fibre Preparation: Raw fibres are selected, cleaned, and prepared for manufacturing. Wool is washed to remove dirt, grease, and impurities.
Carding: Fibres are separated, untangled, and aligned to prepare them for spinning.
Spinning: Prepared fibres are twisted together to produce yarn of the required thickness and strength.
Fabric Formation: Yarn is converted into fabric using industrial weaving or knitting machines, depending on the desired blanket structure.
Dyeing and Printing: Colours and decorative patterns are added to the fibres, yarn, or finished fabric.
Washing and Drying: The fabric is washed to remove excess chemicals and impurities, then dried using industrial drying machines.
Finishing: Processes such as brushing, raising, shearing, and softening are applied to improve the blanket’s softness, appearance, and texture.
Cutting and Stitching: The fabric is cut into the required blanket sizes, and the edges are stitched or finished to prevent fraying.
Quality Control and Packaging: Blankets are inspected for defects, correct dimensions, and fabric quality before being folded and packaged for distribution.

The Future of Blankets

Modern blanket manufacturing increasingly focuses on sustainability, comfort, and innovation. Many manufacturers are exploring recycled fibres, organic cotton, responsibly sourced wool, and environmentally friendly production methods.
There is also a growing interest in producing blankets that combine traditional craftsmanship with modern textile technology, allowing manufacturers to preserve cultural heritage while meeting the needs of today’s consumers.

Sources

About the author: Eman is a textile engineer and writer. She received her bachelor’s degree in textile science from Egypt’s Faculty of Applied Arts.

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