Wool sorting and washing
The wool are in raw form so we first clean the wool by our hand eliminating unwanted materials and separate wool as per their natural colur .Then we wash it in warm water to clean it.
Rug Manufacturing Process
Carding
Carding is a mechanical process that disentangles, cleans and intermixes fibres to produce a continuous web or sliver suitable for subsequent processing. The special traditional steel and wooden hand made comb are used for carding.
Spinning
Spinning is the twisting together of drawn out strands of fibres to form yarn, though it is colloquially used to describe the process of drawing out, inserting the twist, and winding onto bobbins. In simple words, spinning is a process in which we convert fibres by passing through certain processes finally winding into yarns. Its also known as “Charkha” in Nepal.
Dyeing
Dyeing means clouring the yarn. The yarn are washed in hot water in big pot. Different formula are used for dyeing the yarn in order to get the desire colour.
Weaving
The craftman starts weaving the rug by studying the hand sketch graph of the design. The graph provide detail information about the scale , colur switching and the quantity of yarn to be used.
Trimming
Here the rug are trimmed evenly.The unwanted pile are trimmed out smoothly to give the rug clean and shiny looks.
Washing and drying
After the rugs are trimmed its washed properly.the wooden flappers are use to clean the rug. Different liquid soaps and softner are used as the materials used in the rug to make it soft ,clean and shiny. It usually takes 4-7days for drying the rug depending upon the size of the rugs.
Streching
In the washing process, the size of the rug slightly decreases. So it is stretched using a square metal frame , hooks and bringing it to the right size and also straighting it. Its take atleast 24 hours to bring the rug into the right size.
Finishing and checking
The rugs are checked. 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.
Packaging
After the approvement by our managers the rugs are then packed.The rugs are rolled and kept inside a heavy plastic bag which is both tearless and water proof. So that the rug dosent get damage during shipment process.