HANDMADE CARPET OF PROCESS


 

The process that creates a hand-made/hand-knotted carpet can beexplained as under:

1-Wool sorting & Washing

Woolis either imported or is bought from nearby markets and is carefully sorted topick out unwanted particles. Wool often carries dust, grease which is removedby washing it thoroughly and is then sun dried for two-three days.


2-Carding
The carding process allows the fibre stand toflow smoothly when spinning. This is also the stage for blending differentwools and to ascertain the ratio of different origins. Traditionally, cardingwas performed by hand and machine carding was introduced when the industrygrew. However hand carded product is still available if a customer so desires.


3-Spinning 

The carded wool isspun into yarn by using a charkha or a spinning wheel. The thickness of theyarn depends on the quality of the carpet and generally a 3 ply yarn is used. 


4-Dyeing
The traditional pot dyeing method has beenlargely replaced by machine dyeing in closed  Chambers. Dyes containingharmful substances such as AZO are banned and dye-stuffs from  renownedinternational manufacturers are used. These dyes have a high degree offastness. Depending on the weather, the dyed yarn has to be dried in thesunlight for one to three days. Pot  dyeing and vegetable (natural) dyeingare still being used by some manufacturers.


5-Carpet Knotting
Knotting is an art. Weavers who weave on aregular basis have a very good speed in knotting. They tend to develop thisspeed over a span of time. One or more weavers work on a loom depending on thesize of the carpet. Each weaver makes individual knots row after row. Thedesigns are chartered out on a graph and a map reader or another weaverinstructs the graphic designs to the ones knotting the carpet. The dyed yarn ismade into balls and scissors, iron rod, levers, comb beaters are used as tools.


6-Trimming
Thefinished carpet is taken off from the loom and the designs & patterns aretrimmed by scissors.

 

7-Washingand Drying
Thetrimmed carpet is washed with the fresh water & chemicals. The washedcarpet is dried in the sunlight up to four or five days. 

 

8-FinalTouches
Thedried carpets are given final touches by re-trimming and stretching, where evernecessary. The purpose is to bring the fabric woven in level at the surface.


9-Packing
Allwashed carpets are rolled and wrapped in polythene sheet and is sealed at eachend. Again, it is wrapped in Hessian cloth and sewn. Generally, around 14m2 arepacked in each bale.