Our production process does not use any type of electronic machineries. The whole process from the sheering of the sheep to the packing of the finished rugs is carried out entirely by hand. Manufacturing of the different material rugs uses different process at the first two steps so this page only contains the information of our woolen rug making process :
Wool sorting & Washing
Our Wool comes from High himalayas of Nepal which comes in a raw form right after sheering the sheep. We short the raw wool by hand to pick out the foreign materials such as vegetables and wood particles, and separate the different natural color of the wool. After shorting wool will be washed in warm water to clean out the foreign particles. Our Tibetan wool is 100% pure Tibetan wool from high Himalaya and are not mixed with any other wool to maintain the quality.
Wool carding
Carding is the process of combing the wool so that no fibers are intermingled together and to maximize the purity of wool by removing all the foreign particles if any. Carding helps on spinning of the yarn from the wool. carding is done by the special traditional steel and wooden hand made comb.
Spinning
Spinning is the process of making a yarn. After carding spinning is carried out with a traditional wooden spinning wheel called 'charkha' in Nepalese. in the process of spinning the wool fibers are drawn and twisted to make the yarns in desired thickness, the thickness of the yarn is made according to the knots of a rug, for lower knots like 45-60 knots the yarn will be thicker comparing to the 100 knots yarn.
Dyeing
After the yarns are made by spinning process, the yarns are ready for dyeing. Before dyeing the hank of yarn will be washed with warm water again to ensure the best quality of dyeing. The dyeing is done in a big pot with a wheel burning wooden or gas stove underneath . We use swiss chrome azo-free dye or vegetable dye as per clients demand.
Weaving
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Rug weaving is performed by hand reading graphs of a design which is hanged in front of the weavers on a loom, The graph will be 1:1 scale. Our Carpet weaving is done with the traditional tools like scissors, iron-rod, levers, comb beater, iron hammer etc. This process involves skills and craftsmanship.
Clipping and carving
After rug is weaved and comes out of a loom a surface pile of a rug is then clipped by the traditional big size scissor called 'khapsi', this will smoothen the level of pile evenly and gives a shiny and even surface texture. The design edges will be carved by scissor for the luxurious look.
Washing and drying
After clipping and carving, rug will be washed with the help of long wooden flappers which helps to rub the surface of a pile and to carry out the water properly for faster drying. The natural soap like sapindus and the normal liquid soap is used to wash the rugs. After washing rug will be dried on direct sunlight for about 4-7 days.
Second / final Clipping and carving
After rugs are dried it is again clipped one more time to ensure the even surface and also carved the edges of the design one last time to ensure the perfect and clean design finishing.
Stretching
After final clipping and carving rugs are stretched from all four sides using metal frames and hooks, keeping on a frame for at lest 24 hours. It helps in maintaining the perfect shape of the rug.
Final finishing and checking
After taking rugs out of a stretching frame it is then checked by our professionals. It is mainly checked for the size, shape, surface, designs, stains, etc... This is the most important part and we treat it as a very serious step.
Packing and shipping
After rug is approved by the management it is then packed. We never fold a rug for packing because there could be a fold marks on a rug, we roll the rugs and put it in a transparent heavy duty plastic bag as a first protection, and then we warp a rug with a heavy duty tear and water proof sheets from above. For heavy weight rugs we also warp with a burlaps for extra protection on the transits.
