I had the honour of touring the main location of LennyLamb in Poland a few weeks ago. I am not sure if you are aware, LennyLamb is one of the largest manufacturers of wraps, ring slings and structured carriers there. This company started off in Asia’s apartment June 2008, as soon as the idea was conceived it became a family business. Asia’s husband Michal, her sister, Kasia, and Kasia’s husband Piotr joined in to make LennyLamb the company it is today. They first started by outsourcing their weaving and sewing to various places locally. But as the business expanded, it didn’t make any sense to continue this way. Soon they decided to open their own facility by moving to a small converted farm building belonging to the family. Initially, the entire production was located in one building, where the shipping and coordinating was done in a small side room which now serves as their photography studio. The company has now expanded to several buildings. Though Lenny Lamb is larger, employing a good number of people in Poland, it still keeps its small family aesthetic. Each carrier is made to order, on time, just for you.
Touring the facilities was a blast. I am a very visual person and I couldn’t get over the feast offered throughout the factory. Spools of yarn, fabric scraps, colours everywhere.
I learned so much! It was absolutely fascinating. First we started in the building where the yarn is brought in, sorted, and wound on the warp beams. The amount of work needed to get a warp done is amazing. First, the spools of yarn are loaded on the rack, they are hand strung in a grouping of 500 threads, each done up with a neat little knot. Then the technicians then use the bars to keep the tension where it needs to be. Once the warp is wound and sorted out, it is then threaded onto the warp beams, the knots at the start of the warp are used to secure it into the beam and then a second knot at the end keeps the group of 500 threads separate. Ten of these sets of 500 threads are loaded onto the warp beam and it is a fairly intense process.
From here we went to the BEST and most interesting part, where wraps are made. They had four jacquard looms in operation at the time I visited, and including one Dobby loom. Each loom had a different weave on the go. The first set was a cross weave, which you can see by looking at the crossing reeds, and each piece that is woven has two repeats on it. It is much easier to keep some looms with it’s own weave style because it saves time, otherwise to change the configuration is quite time consuming. This is one of the reason there are so many!
Each spool has several runs of fabric on it, and is separated by a bit of plain weave, allowing for easier cutting and sorting later on. There is a really neat bit of waste that is created in the weaving process, the ends almost look like feathers, like each run creates something that will reminds me of how this will fly to families all over the world. The remainder of the warp is then saved and reused whenever possible. The spools of completed fabric are stored throughout, and they are a feast for the eyes.
From there, the fabric either moves to the sewing room to be cut and trimmed to create wraps, or it heads to the cutting room to be treated and turned into your favourite structured carrier. Lenny Lamb makes a series of structured carriers, from a full buckle, onbuhimos and mei tais (meh dais). As previously mentioned, this is a family operation and runs are small. This allows Lenny Lamb to do one thing, make each carrier to order. Literally. When you press buy on their website, that fabric gets removed from the shelf and that carrier gets made just for you. When a store orders an amount puts in an order for their shop, that order is made specifically for them. It’s tailored to your needs, to your life, to your hometown.
The small, just in time nature of their business also allows Lenny Lamb to do many new innovative designs and colourways, keeping their product line fresh and new. When I arrived, they had just put out a new colour in their horse weave and the popularity of it meant the orders were being processed right before my eyes. It has just been released the day before.
As a knitter and a educator, I have a true love of fabric. The scraps everywhere were grabbing my attention left, right and centre. The useable scraps from the cutting room are then cut, sorted and trimmed to make up the bundles of scrap fabric that are also available for sale. Nothing is wasted, I even spotted a scrap that was being used to clean the machines. Waste not want not! (Look away if using wraps scraps for cleaning makes you cry…)
And that is one of the main benefits of having everything located nearby. The environmental footprint is much smaller than other operations. The yarn, the webbing and the buckles are the only things shipped in to make each carrier. The winding of the warp, the cutting, the weaving, and the sewing are all within walking distance of each other. For some companies that aren’t able to weave their own fabrics, due to smaller fabric runs or other factors, the fabrics are designed in house and woven offsite. These rolls then have to be shipped to various locations for find construction.
Another benefit of having a fully functional factory is the ability to test out different concepts before deciding if they should be integrated into their carriers or should just remain an experiment. They can test out the quality of the weave, the weight and the workability as a wrap without having to wait. Many companies have to send the design off to have a test piece woven elsewhere for them to evaluate. Not here! I was even lucky enough to see a really innovative experiment – I was shown a test project. It was a two sided fabric, where one side you see the boy looking out, the other side you can see the boy’s back and his shadow and from the rest of the figures too! Though far too thick for wrapping, who knows what might develop from here?
Once your order is prepared to your specifications, it moves to quality control, where it is checked prior to labelling and packing. Shipping and receiving is directly on the other side.
It goes from this family-run business right to your local shop or straight to your home.
Débora was invited to visit Lenny Lamb September. This article is as a result of her visit. Two live interviews were done by Lenny Lamb, one in Polish and the other in English. Pop in and take a listen! Débora would like to thank the Lenny Lamb team for making her visit memorable.
Link to the LennyLamb story: https://en.lennylamb.com/web_page/10735
Débora’s interview with LennyLamb Polska about carrying in Canada: https://www.facebook.com/147801012269544/videos/484787701904205/
Interview on LennyLamb to describe why I visited Poland: https://www.facebook.com/lennylamb/videos/10154725820902484/