Process.
Rug Manufacturing Process.
1 | Yarn
Wool is either imported or is bought from nearby markets and is carefully sorted to pick out unwanted particles. Wool often carries dust, grease which is removed by washing it thoroughly and is then sun dried for two-three days.
2 | Spinning
Spinning involves two steps Carding and Spinning- Carding is sometimes done by hand with help of carding brush or on carding rollers run by hand. The carded wool is spun into yarn by using a charkha or a spinning wheel. The thickness of the yarn depends on the quality of the carpet and generally a 3 ply yarn is used
3 | Dying
Talking particularly about the Solid Dyeing process, in this case, the yarns are first bundled together in small quantities using a metallic wire. The long lengths of these yarns are then put on a roller which is placed above the dyeing solution. The roller then slowly dips these bundled yarns into the solution.
4 | Designing
Before any wool gets dyed, before any weaving gets done, we must, of course, determine what rug we are going to make! In that, the designer envisions the rug, determines its make, colors, style, and size.The CAD/map is created through a rug software program. In the final CAD/map there is literally one pixel for every individual knot.
5 | Weaving
The weaver was considered untouchable in the India of the past. A definition that was misinterpreted, truly fitting only to their skill. A range of weaving techniques are used to create different types of rugs and the technique can determine the quality, design, price and even their durability.
6 | Washing
The finished weaved carpet is then goes for washing i.e. Chemical Finishing. Washing removes dust, fine particles, swelling of fibers, soft fibre and finally, the required softness and luster are achieved. Washing is done with water mixed with soap, bleaching powder and other natural chemicals. Washed carpet is dried in sunlight for 4-5 days.
7 | Stretching
Stretching is done to make the sides straight otherwise the carpet has some curved edges.
8 | Clipping
Clipping is the process of cutting the borders of the motif on the carpet which gives detailing to the motif. It is also done by decreasing the pile height of the piles other than that of motif. This way the motif seems to like protrude out of the background and gives a good look to the carpet. The embossed motif is sometimes of different fibers also.