All Quilts
Alpaca Range
Pure Fine Merino Wool Quilts
Kelly & Windsor
Our Materials and Manufacturing
Behind The Scenes
Crafting Australia's Finest Natural Fibre Quilts
As a fully vertical manufacturer, Kelly & Windsor controls every stage of production — from sourcing premium Australian-grown alpaca and pure fine merino wool to the final stitch. This hands-on approach ensures each quilt in our luxury collections meets the highest standards of craftsmanship, comfort, and quality.
We believe our people are our greatest asset, and we actively encourage staff involvement across all areas of the business. This collaborative approach has led to many innovations, including our signature UltraSoft quilting design — a breakthrough that delivers unmatched softness, warmth, and a flawless finish. Every quilt we create is a reflection of Australian-made excellence, natural fibre luxury, and the dedication of the Kelly & Windsor manufacturing team.
Alpaca Fleece - the essential raw ingredient
Alpaca fleece is one of the world’s most exclusive natural fibres, representing less than one-hundredth of one percent of global sheep wool production. This rarity makes it highly sought after for luxury bedding and textiles.
Like all natural fibres, alpaca fleece quality can vary from season to season, from one stud farm to another, and even depending on which part of the animal it is shorn from. At Kelly & Windsor, we carefully select only the finest grades to ensure exceptional softness, warmth, and long-lasting performance in every quilt.
Expert Alpaca Fleece Grading – Ensuring World-Class Quality
Classing alpaca fleece is a specialised skill and a vital step in creating our premium bedding. At Kelly & Windsor, each incoming fleece lot is meticulously assessed for fibre thickness (measured in microns), fibre length, colour, consistency, and the presence of any vegetable matter.
Only fleece that meets our strict control specifications is selected for our quilt collections. This rigorous grading process ensures every Kelly & Windsor quilt is made from alpaca fibre of world-class quality — delivering unmatched comfort, warmth, and luxury.
Only the Finest – Sourcing Materials for Luxury Quilts
While alpaca fleece is our signature fibre, Kelly & Windsor also sources a range of premium raw materials for our quilt collections — including pure fine merino wool, high-quality fabrics, trims, and packaging. Wherever possible, we buy from Australian suppliers, supporting local industry and ensuring traceability.
If certain materials are not available locally or do not meet our standards, we source internationally — but only from trusted partners who share our commitment to excellence. Every material, from fabrics to trims, undergoes a thorough inspection against our strict specifications to ensure the luxury and durability that define Kelly & Windsor quilts.
Precision Carding – Perfecting the Alpaca Fibre
Once graded, sorted, and prepared, the alpaca fleece is combed on specialised carding machinery to align the fibres and maximise loft and evenness across the quilt. This process — a craft refined since the industrial revolution over 200 years ago — requires exceptional skill and experience to achieve the perfect balance of fibre alignment and consistency.
Pure alpaca fleece presents a unique challenge in carding due to its smooth texture and long fibre length. At Kelly & Windsor, we have adapted and enhanced traditional carding equipment, developing techniques that allow us to card and comb alpaca fleece in wide-width configurations and with various weight options. The result is a perfectly prepared fibre layer — a testament to our world-class expertise and commitment to quality.
Cross Lapping – The Hidden Secret to Quilt Quality
Cross lapping is a critical step in creating the perfect quilt filling. After carding and combing, the alpaca fleece forms a delicate, gossamer-thin web of fibres. This web is then mechanically cross-laid, layer upon layer, to create a multi-layered fleece with the precise weight and width required for luxury quilts.
At Kelly & Windsor, we use state-of-the-art, computer-controlled cross lapping equipment to ensure absolute precision in the layering process. In our Pure Alpaca Gold 500 quilt, for example, the filling is made from twenty-six ultra-fine layers of pure alpaca fleece — optimising loft, warmth, and durability for a truly world-class quilt.
Quilting – Australia’s Best in Craft and Technology
Once the perfect fleece filling has been created, it’s time to secure it within the quilt. At Kelly & Windsor, we combine the latest quilting technology with decades of expertise to produce Australia’s finest bedding quilts.
Our two state-of-the-art quilting lines allow us to create a wide range of alpaca and wool quilts in different weights and sizes — from standard Australian dimensions to super king and extra-large sizes for international markets, including North America. This flexibility ensures every quilt is stitched to perfection, maintaining the loft, warmth, and premium finish that Kelly & Windsor is known for.
Trim Design - Innovation and Style
After quilting, each quilt and underblanket is expertly bound with an edge trim, and care labels are precisely sewn in place. This stage requires exceptional skill and attention to detail — particularly for the distinctive trims featured on our Alpaca Gold quilts.
Once binding is complete, another quality inspection is carried out to ensure the trim is perfectly aligned, the stitching is flawless, and the product meets our exacting standards before moving to the next stage.
Final Inspection – Our Promise of Quality
At every stage of production — from receiving raw materials to the final stitch — Kelly & Windsor implements strict quality inspections to ensure our products meet the highest standards. The last step in our manufacturing process is a meticulous final inspection, where each quilt, duvet, doona, underblanket, and pillow is individually checked before being packed.
The packing date is recorded for every item as part of our Total Quality Management (TQM) system, enabling full product traceability. Our guarantee is simple - the finest quality materials, the highest manufacturing standards, 100% Australian Made.
We partner with trusted, premium carriers who have been delivering our products for many years, ensuring every order arrives promptly and in perfect condition — just as it left our workshop.