Designing, Rendering & sketching
Our professional designers commence designing your rugs with a lot of creativity and ingenuity in our design studio where impeccable imagination meets reality. Our team of designers are always dedicated to use unique approach towards designing a new masterpiece that are inspired by many traditional and classical rug weaving or by contemporary and modern art forms. Design once complete and concluded, our artistic team will finalize color combinations suitable for every requirement involved, some designs may require a bold, vibrant color combination while others may require soft, sophisticated or elegance color combination. Approval of the rugs design and renders for the clients will carry us further in rug making process.
Dyeing
After the authenticated yarns arrives in our warehouse, we ready yarns for dyeing procedure. Prior to dyeing the yarn, the hank of yarn will be washed with warm water again to ensure the foremost quality of dyeing. Big pot with a wheel burning wood or gas stove underneath is used for dyeing the yarn. Our team uses environmental friendly Swiss chrome Azo-free dye for our dyeing procedure to encapsulate the best desired shades for our yarns from muted or vibrant to dusky or pastel, the wool is dyed with perfection and precision. The procedure is done above 100 degree Celsius of temperature to acquire and accomplish color fastness. After the dyeing procedure is concluded, wet dyed yarns are sun dried in open space with adequate sunlight throughout the day.
Weaving
The yarns which are dyed to perfection is now made into a ball of yarn. The approved designs from our design studio apprehended by professional rug designers are now transformed into a life-size graph, ‘naksha’ or blueprint which becomes a perfect guide for our weavers. Rug weaving procedure is performed by highly skilled weavers by hand, studying the graphs of a design which is hanged in front of weavers on a loom. Our Weavers uses traditional tools like iron-rod, scissors, comb beater, iron hammer, levers and many more for rug weaving process. This process needs high precision and craftsmanship to accomplish the desired output, each of our weaver makes individual knots row after row. The graph of designs is studied by a map reader or another weaver, who instructs the designs to the ones who are knotting the rugs and it is carefully carried out with precision through use of various traditional tools.
Our weavers wove the rug on vertical looms on which the warp i.e. vertical threads that forms backing of the rugs is wound. The Pile of the Rug is made by looping yarn around two warp cotton threads, then around a guide rod which lies perpendicular to the warp. The looping continues till a row’s end is reached. The rod is hammered tight against the row below whenever a row is completed. The weaver next cuts the pile open by cutting along the rod with a very sharp and sturdy knife. The rod is withdrawn, and the row is pounded down again with a comb against the prior row. The weaver then inserts the two or three weft threads at the top of the row, slides the metal rod back in above the weft, and begins a new row.
Washing and drying
After the weaving process is accomplished, rug is off the loom and will be washed thoroughly with the aid of long wooden flappers which helps out rub the surface of a pile and to carry out the water properly for swift and rapid drying. We use all natural, environmental friendly and non-toxic soaps for washing of the freshly weaved rugs which cleans the impurities, fix the colors and give shine and charm to rugs and moreover, keeps the integrity of rug to perfection. After the washing of rug, we then transfer the wet rugs to direct sunlight for about 4-7 days for drying.
Clipping and carving
After the rug is washed and completely dried, It has now been clipped to smooth the surface and remove any irregularities and abnormalities in the rich pile’s height. We clip the rugs with traditional big size scissor called ‘Khapsi’, this will evenly smooth the pile level and produce a shiny and even surface texture. The goal is to make the fabric woven in level at the surface of rug.
Following the clipping process, our staff painstakingly trims and carves the edges of the designs to ensure the highest quality and a precise and clean design finish.
Stretching
Stretching of rugs starts prominently after the clipping and carving. Rugs are carefully stretched from all four sides using big metal frames, rods and sewing all four edges of the rug in the frame, we always keep our rugs for at least 24 hours which in turn helps in maintaining the perfect shape of the rug.
Behind the rug, an adhesive is applied, and it is stretched out in the sun on a stretching frame. The rug absorbs the adhesive and dries in the sun, straightening the edges and maintaining its elegant shape to perfection.
Final finishing
Following the stretching process, rugs are taken out of a stretching frame and it is then thoroughly inspected by our professionals. It is mostly examined for any size, form, surface, designs and stains irregularities and final touches are applied if need be, to give our rugs a perfect precise shear, trim, and finish our professionals use a variety of traditional tools to do so.
Packing
After the final finishing of the rugs and examining it to its excellence, the finished rugs are rolled and wrapped in polythene sheet with each end sealed. It’s sewed and wrapped in hessian burlap fabric once more. Heavy-weight carpets are shipped overseas in a wooden box for extra protection and care during transport.
The finished rug from our warehouse is packed and shipped all across the globe to our customers.