The entire manufacturing process, from shearing wool to finalize the rug, is handmade so that our rugs have all the properties that original wool or fiber has. Not a single machine has touched our whole process. Machines weaken and damage the original properties of wool or fiber (e.g. lanolin and oil) and can’t produce such qualified, comfortable and durable rugs like those of handmade. But some equipment like wood and metal brush, carding and spinning machines are indispensable since they have been used from ancient times. A genuine handmade rug can lasts 100 years since it is washable and highly qualified but machine-made rugs can merely last 2-7 years. Besides that, handmade rugs are work of art and skill that make its owners proud for a long time.
We provide here the manuf We’ve been doing so for decades. Manufacturing process of rugs step wise to understand simply:
(This should be shown in slide with pictures and description)
Step 1: (Shearing and Washing)
We shear the wool from sheep, sort out the desired raw materials and wash in warm water to clean completely.
Step 2: (Carding)
Using the traditional handmade metal and wood comb, those washed wools are combed so that it removes all unnecessary materials.
Step 3: (Spinning)
Now we make yarn from the wool through spinning using a traditional spinning wheel called “Charkhaa” in Nepal. We sort out the yarn, of desired thickness, from the wool in this process.
Step 4: (Dyeing)
After washing the hank of yarn in warm water, we dye it in a big pot. Dyeing depends generally on the clients demand, like azo-free dye or vegetable dye.
Step 5: (Weaving)
Using scissors, iron-rod, levers, comb beaters etc., we weave the dyed yarn by hand reading graphs (1:1 scale) which is hanged in front of a weaver.
Step 6: (1st Clipping and Carving)
This weaved rug is then clipped by a big scissor called “Khapsi” to smoothen the level of pile and shine the surface. Then the edges of this rug are carved using Khapsi to get the desired shape.
Step 7: (Washing and Drying)
Then we wash it by long wooden flappers to clean every part of it. After then, we dry it for 7 days in sunlight.
Step 8: (2nd Clipping and Carving)
Just to ensure the even surface and perfect designing, we again clip and carve the dried rug.
Step 9: (Stretching)
Then we stretch all its four sides to a desired frame for at least 24 hours using metal frames and hooks.
Step 10: (Finishing and Checking)
Undoubtedly the most important step, professionals will check its size, design, surface, quality and shape, stains etc very carefully.
Step 11: (Packing)
Since folding may leave permanent marks, we roll all our rugs and put it on a heavy duty plastic bag for first protection. Then we wrap it with a heavy duty tear and water proof sheets from above.