I think it’s a good time for a look back at who and what Baavet Cyf is all about and how it all started?
It’s a saga, a long one, I hope you can hang in there!
I have been writing this blog now for a very long time and I usually write at night or the early hours of the morning. This morning I was woken up by the light, not by the day light, but the moonlight. If you live in an urban environment, and most of the human race does now, you will have been artificially cut off from the wonders of a full moon lit night by the scourge of the modern world, light pollution, the street lights and neon signs. On a dark evening you can no longer see the wonders of our starry sky with the silky, milky way, snaking across it (oh you smooth talker you). Constellations like the plough (the great Bear) and the belt and sword of Orion blazoned across a sky amidst billions and billions of stars that make up the universe we live in that seems to go on for ever. In a city not only are the stars of the night sky dampened by the glare of electric light but the horizon line is blocked by the lines of buildings.
But up here where we live the sky meets the land or in our case the sky meets the mountains and the sea our horizon line seems to go on forever.
In fact it can be so light from the moon that it can cast shadows on the ground or we can even go out and have some fun, you can see the picture of me with Moss and a body board when we were out in the snow at night sledging. http://baavet.posterous.com/the-winter-solstice-continued

Snowdon at its best with a covering of snow in winter
So I love living in this little country of Wales with its mountains, sea, ancient language, standing stones, stone circles and its rocks that go back to the dawn of time. But most of all I love the space, which seems endless here, with not just wonderful moonlit nights but amazing sunsets across the sea. Here I can breath and feel free. I wish I were Welsh especially this weekend when the whole of Wales, and I really do mean the whole of Wales was holding its breath waiting for a miracle to happen on a rugby pitch 12,000 miles away.
There, the spirit of a nation was going to be played in front of television cameras watched by millions of people around the world. To be Welsh means not just your country but your language and Rugby football. It’s part of the culture even if you don’t really watch or support the game.
On this occasion the dream was not to be; and history was not made; and Wales are not heading to a World cup final. And I put £10 on Wales to win the cup! But I for one think that the present Welsh team could now be the best in the world, if only they can play with 15 men!
For now lets get back to making a Welsh Baavet which also could be the best in the world.
My wife Lesley is Welsh through and through, although from her accent you would never tell, she was born near Treorchy, well Llwynypia hospital really and most of her family still live in the area. You only know she really is Welsh when she supports any other team that’s playing England at rugby!
My love affair with Wales started from the day, aged 15 when I came on a school camp to Snowdonia. It was the start of a lifetime of adventures I have had in not only the mountains of Wales but all over the world.
So when we came here 13 years ago to live it was almost like coming home and it was the start of the greatest adventure of my life and probably Lesley’s too. Since then we have been running our traditional sheep and cattle farm in the Snowdonia National Park. You can catch up with us on the rest of our story and many more in our blog.

These are our two working Border collies Gwen and Moss although Gwen has retired now. Some of you may have read some of their adventures on our blog already. (Another shaggy dog story)
During our time on the farm we have had to diversify into other things to make a living. As we both have a background in the outdoor world our first venture was into adventure activities for visitors to the national park. Then, after a few years, we converted some of our barns into high quality self catering.
You would think that this would be enough work running 3 different businesses, especially in the summer, and you would be right. In fact Lesley has already cut back on the adventure activities to concentrate on the self catering while I looked after the adventure stuff, but age was taking its toll on me and I was keen to retire from active adventure service.
Then just over two years ago I had the bright idea for another farm diversification scheme which I hoped would mean spending more time on the farm and me giving up adventure activities.
The idea was quite simple, to reinvent the blanket and stuff wool into a duvet, just how, I didn’t know but it couldn’t be too hard could it? And that dear reader was the biggest under statement of my life!
My wife Lesley felt that perhaps the world wasn’t quite yet ready for a wool duvet and that we should call it a Baavet. So the idea was conceived, given a name and all we had to do was turn the idea into a reality. And that, dear reader, was the next big understatement of my Baavet life. (For the unabridged version of how it all started with my vision on the road to Damascus check out… http://baavet.posterous.com/the-truth-about-the-baavet
But what started as a simple plan to help ourselves and our farming neighbours has grown into a full blown commercial operation far beyond our original expectations due to our involvement with parts of Yorkshire and Lancashire which were once home to great British textile industries. Having seen at first hand the terrible demise of these industries and British manufacturing in general we are now on a mission together with many other people to help in some small way, if we can, to restore British manufacturing, not only at home, but who knows we may even export to China!
But there has also been another important aim and that is to carry out our business both in an eco friendly way and hopefully an ethical way.
After the initial euphoria of thinking I had invented the wheel we were quite surprised to find out from son Christian of Documentally fame that wool duvets were already being made but never the less he thought it was a good idea and he would certainly tell his friends on the internet about his crazy father’s idea… if we could actually make them.
“Of course we can,” I said. Why did I ever open my big mouth?
So we naively decided that if someone else could make them abroad then we could find someone in the UK to make them for us and decided to give it a go. And that, readers, was yet another big under statement of my Baavet life!
There seems to be a pattern developing here.
Our first port of call was the British Wool Marketing Board’s wool depot where all the farmers of North Wales take their wool for grading, which is only 12 miles away from us. We met Merion, the manager who was extremely knowledgeable about wool in general, and wool grading and wool quality in particular and he really put us on the road of a long process of discovery.
I will never forget him saying “Put your hand into the fleeces in that wool sack. Can you feel how warm it is?”
“Wow, yes it really is” I replied in astonishment.
“Well those sheep were shorn four days ago and it’s still warm now.”
I knew then we were possibly onto something really good and possibly something really big.
Full of enthusiasm we formed a limited company and trademarked the name Baavet after buying some domain names.
Then, as everyone in business does, we looked at the competition closely, as in… we bought their wool duvets and took them apart. Some weren’t even 100% wool but had polyester inner linings to attach the wool to or had a polymer bonded into the wool to make the wool stable for manufacturing into the duvet. We should have realised then that making a wool duvet just wouldn’t be that easy.
Merion had put us into contact with the Wool Testing Authority which fortunately for us was only 20 miles away. They test all the wool that comes on the market for the whole Northern Hemisphere! Tim and his associates at the WTA did everything they could to help us. They tested the competitors wool so we had an exact profile of that wool some of it was supposed to be a merino wool mix, but tests showed there was very little Merino in it, hardly surprising really from what we know now about the different types of wool but it was a decent quality wool mix with very little modulation and a good staple length.
The WTA then started to test local Welsh wools for us and they were able to give us profiles of these and other British wools to help us find a quality of wool to match our competitors and be the best type of wool suitable for duvets.
In the meantime while this was all going on we were on the hunt for someone to manufacture our Baavets. We contacted the British Wool Marketing Board. They were particularly helpful in giving us names of companies that might possibly help.
The list wasn’t very long, which is hardly surprising knowing the state of British manufacturing, but even we were shocked when we went in search of companies to card wool and then somehow quilt it into a duvet. We would arrive at huge mills only to find them semi derelict with someone just occupying a corner of the building that once proudly boasted being the best in the world or we would often arrive at a small back street and find a small building with quilting machines working away.
Several companies offered to make our Baavets in China or Europe but that wasn’t the idea either although as time wore on I thought that that would be the only way we would ever make them. But Lesley was adamant not to go down that route and instead chose the very difficult road of still trying to make them in the UK.
Then we met David and his son, also called David, who are both engineers, and who had a Mill producing manmade polyester foam for the bedding industry but they also had a wool carding line in Huddersfield. We got on well from the very first moment we met. They liked our Baavet idea and although they had no experience of quilting they were keen to be involved in carding our wool especially as they already carded wool for a Welsh company specialising in organic wool mattresses in South Wales. He also had a very experienced carding man, Roy, whom he had every confidence that he could card the wool into a very fine state which we would need for our Baavets.

David and Roy inspecting a piece of quilting
We eventually found someone with quilting experience near Manchester, in fact he built quilting machines and he was prepared to try to move carded wool from David’s mill and quilt it for us in his own mill. We did actually make our first Baavets this way but the problems involved made it uneconomic and so he helped us to buy a quilting machine and set it up in David’s Mill.
But this was not a simple operation as David and his son have had to adapt their factory and carding line to take a quilting machine.
Setting the quilting machine to run properly in a completely new environment has taken two quilting engineers plus David and his son and months of frustration as things have had to changed, new parts made, reworked, and tweaked time and time again to get over problems to set up what has become the first carding/quilting wool production line in the UK.

Steve the latest member of the Baavet team recruited to operate our HMS Baavet. (Well he looks like a captain on the bridge of his ship even if it is only a quilting machine.)
At the same time as solving the quilting problem we also had to find a company that had the machinery and the expertise to individually make up the duvets. We actually found someone quite quickly and quite near to the carding mill and plans were made for them to make our second generation Baavets. But before that happened the company went into liquidation, another victim of the credit crunch and globalisation.
That’s when we decided to make them ourselves, in Wales. There then followed several months of finding the right industrial sewing machines for the job and getting training to use them and finding the right kind of premises to work in, as it couldn’t be done on the farm.
We have had to rely on the skills and experience of a whole group of people from pedigree sheep farmers to wool merchants, wool graders, scourers, and cotton merchants all coming together in the UK to make a quality product.
Son Christian did put out the word of the Baavet to his friends out on the World Wide Web and as a result of that the Baavet sheepy icon was born thanks to Richard Mackney and his inspirational design. It was just what we wanted.
But the great thing is that all of the people and companies involved are small and often owner operated and somehow they how survived globalisation which has devastated so much of British industry, but only by the skin of their teeth.
Believe me Baavets are made by people with true British grit.
See.. 'How a Baavet is made'.
But we couldn't ever have got this far without the support of you, the general public who have told us from the start that they love our Baavets. When there was a way to make them better we have always been ready to listen and adapt. The support really has been overwhelming especially in those dark days when everything goes wrong. And we continue to listen and continue learn from the people that count and use our products, our customers. As a result, over the two years our product has got better and will continue to do so.
It really has become more than just an idea, much more than just a duvet; it has become a very British Baavet.

A very nice Welsh lady called Haf (her name means summer) and Lesley at work in our industrial unit in Harlech making Baavets
And our latest product after 6 months in development… the Baavet hair piece (just to show we haven’t lost our sense of humour.)

No its not … it’s our Pillows, but yes, it did take us 6 months of trialling different wool fillings before we put them on sale. http://www.baavet.co.uk/pillows.html#mini
And is everything ‘tickerty boo’ now, is everything running smoothly, you may ask, is the quilter now behaving itself? Does anything ever run smoothly in manufacturing I ask myself? I don’t think so.
The adventure is far from over and there is more hard work and no doubt disappointment and heartache ahead.
But never mind because ‘this time next year Rodders, we will be millionaires’ ...or at the very least we'll still be trying to make the best natural bedding. We'd be happy with that.