All about our Indian-made rugs
Making 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 colours, shape, design and materials make our brand special. This is an essential step that determines the rest of the production process. Once the design has been created by hand, we create a model of the carpet 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 such as jute, wool, cotton, silk and recycled synthetic fiber (PET). The choice of materials depends on the style of carpet you want to obtain.
Dyeing : The yarn dyeing process for carpet production in India is an essential step in achieving colorful and vibrant carpets. Here are the general steps in the yarn coloring process:
- Yarn preparation: The raw yarns are cleaned and prepared for coloring. Impurities are removed with a brush and the wires are washed in hot water to remove any dust or dirt that might affect the coloring.
- Yarn dyeing: The yarns are then immersed in dyeing vats, which contain natural dyes. The tubs are heated to keep the temperature constant, allowing 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.
- Drying of the threads: The threads are dried in the open air. This helps to ensure that the threads do not shrink and retain their shape and color.
- Yarn Winding: The dyed and dried yarns are then wound into spools for further use in carpet production. Spools are labeled to show the color and amount of threads in each spool.
Weaving : Indian carpets 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 thoroughly washed to remove all dirt and impurities. This step is important to ensure the quality of the final carpet.
The Finish : Edge Bonding: The edges of the rug are then bonded to prevent them from fraying or tearing. This can be done using cotton or woolen threads, which are sewn around the edges or using a technique called "serging" 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 any defects. Any imperfections are corrected before the rug is ready for delivery.