All about our Indian manufacture carpets
Manufacturing a rug in India involves many steps, which we detail below:
The design : The first step is the design of our new collection. The choice of colors, shape, design and materials make our brand unique. It is an essential step which determines the rest of the production process. Once the design is created by hand, we create a model of the rug using computer-aided design software. This model will serve as a guide throughout the manufacturing process for our workshops in India.
The choice of materials : Indian rugs can be made from a variety of materials like jute, wool, cotton, silk and recycled synthetic fiber (PET). The choice of materials depends on the style of carpet you want to obtain.
Coloring : The yarn coloring process for carpet production in India is an essential step in achieving colorful and vibrant carpets. Here are the general steps of the thread coloring process:
- Yarn preparation: The raw yarns are cleaned and prepared for coloring. Impurities are removed using a brush and the threads are washed in hot water to remove any dust or dirt that could affect the coloring.
- Yarn dyeing: The yarns are then dipped into dyeing vats, which contain natural dyes. The vats are heated to keep the temperature constant, which allows the dyes to penetrate the yarns evenly. The yarns remain in the dye vats until they have absorbed the desired color.
- Yarn Washing: The dyed yarns are then washed several times to remove any excess dye and make them ready for the next stage of production.
- Yarn drying: The yarns are dried in the open air. This ensures that the threads do not shrink and retain their shape and color.
- Yarn Winding: The dyed and dried yarns are then wound into bobbins for further use in carpet production. Spools are labeled to indicate the color and quantity of thread in each spool.
Weaving : Indian rugs are woven by hand on traditional looms. The warp threads are attached to the loom and the weft threads are woven through them to create the pattern.
Washing : After weaving, the rug is washed thoroughly to remove all dirt and impurities. This step is important to ensure the quality of the final carpet.
The finish : Edge Fixing: The edges of the rug are then fixed to prevent them from fraying or tearing. This can be done using cotton or wool threads, which are sewn around the edges or using a technique called "overlocking" which creates a raised border.
Final cleaning : The rug is thoroughly cleaned to remove any excess fibers or dust. This can be done using a vacuum cleaner or a soft brush to remove debris.
Final inspection : The rug is carefully inspected to ensure that it is perfectly finished and free of defects. Any imperfections are corrected before the rug is ready for delivery.
Manufacturing a woven rug in India is a long and complex process that requires expertise and experience. Indian artisans are renowned for their know-how and mastery of this traditional art, which has been passed down from generation to generation for centuries.
