RUGS MAKING

RAW-MATERIAL

Raw Material Selection is one of the key part in the whole rug making process. The sheen and the feel of the finished rug highly depends on the way these raw materials are selected, spun, dyed and washed. These are also known as also known as a feedstock.  Most commonly used materials in hand knotted rugs are wool and silk.

DYING OF WOOL

Dyeing is the application of dyes or pigments on textile materials such as fibers, yarns, and fabrics with the goal of achieving color with desired color fastness. Dyeing is normally done in a special solution containing dyes and particular chemical material. We are capable to do all kinds of Dying and have our own Dying Plant. Different dyes used by us includes all kind of Natural Dye, Herbal Dyes, EZO Free Dyes, Chemical Dyes as per the need of Client/Importers

Depending on the weather, the dyed yarn has to be dried in the sunlight for one to three days.

DESIGNING

Our design department, which is the backbone of our rug creation process, has an intimate understanding of the weaving medium and knowledge of contemporary art and design. We have the capabilities to customize colors of up to 100 shades of the same hue. You may also have 3000 colors to choose from, which can be seen both on screen and in wool colour poms. Our creations are only limited by our own imaginations. To give you the best possible idea of how the rug would look like in real life, the rug can be placed in a computer-generated room- or even on a photo of your own. Using our specialized technology, we are able to demonstrate the texture of a variety of rugs; including different combinations of wool and silk, carving, high, low and loop pile.

HAND TUFTED WEAVING PROCESS

Preparing the loom-The loom is the foundation of the carpet. The weavers prepare the loom with the predetermined number of warps (taana) for the loom through which the yarns would be woven. Our authorities make sure that the correct yarn tufts, nakshas, and material are supplied to the weavers.

 The wefts (bana) are systematically hung in a ball (kabli).

Different tools used at the loom include: Gucchi – poms, Gucchai – for straightening the entangled knots.

Weaving- Weaving carpets require definite skills and a certain level of expertise on the part of the weaver.

The construction of a rug makes all the difference in terms of look, texture, quality and durability. Hand-knotted rugs tend to be higher in quality because of the intensive labor required. Weavers tie individual knots to the vertical (warp) yarns that run the length of the rug. These knots create the surface, or pile, of the rug. Generally speaking, the more knots per square inch, the more durable and valuable the rug. Rugs come in a variety of densities, ranging from up to 30 knots per inch (very coarse) to 290 knots per inch (very fine). Finely knotted or finely woven rugs are usually the most desirable. Hand-knotted rugs have a fringe on the ends and do not have any sort of backing on them. 

Tools used: chura is a metal blade, forged to cut the knots evenly without damaging the yarn.

 Image: Before starting the weaving process, a designer draws the design on a white paper and a graph is created. After that, weaver adjusts handloom according to the size of the carpet. First, they stitch the cotton cloth as a frame on the loom which is called primary cloth and then draw a design on it. When CAD is ready then they start weaving using a gun machine. Gun machine is used for inserting wool material into the frame according to the design.

Craftsmanship with skill — envisioning design from paper to loom

THE WASHING PROCESS

The washing processes define the final look and feel of the carpet. It cleans all the foreign particles and gives the carpet a soft look. This also prevents shrinkage and shredding. Later the rug is left under sunlight for drying for about four-five days.

FINISHING OF RUGS/CARPETS

Gul tarashna-After all the rugs are weaved and washed, we have dedicated a team who takes care of finishing of Rugs/Carpets. All the finishing process is done in house. This is done in order to achieve clarity in design and achieve the pile height. The surface of the rug is smoothening out by removing extra hanging fibers. Pointed sharp scissors are used for this leveling. This trimming brings out the clarity in the design of the rug.

Binding

Binding/Pechai – Carpets are bound with wool and silk on their sides for stability. The number of stitches is determined by the intricacy and density of the carpet.

Latexing Process

Carpets are back coated with latex to make them more durable and easily handle. A good back coating system serves to anchor the pile and prevent minimizes loosening of the pile, pull-out of the tufts, , reduces shedding, provides dimensional stability and prevents fraying during cutting.

Stretching

Stretching or tanai is done to make the sides straight otherwise the carpet has some curved edges.

Packing

The process of Rug Packing at Super Rugs is conducted in the following process:

  1. The manufactured carpet is rolled around the card board pipe.
  2. A white transparent plastic sheet is wrapped around the carpet.
  3. An adhesive tape is tied around to secure the plastic over the carpet.
  4. The brand identification mark on a tag, is sewn below the pile. The tag carries the logo and name of the company along with the care instructions.