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5/9/2016 CarpetManufacturingProcessProcessofHandMadecarpets

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CarpetManufacturingProcess
ManufacturingProcess>>HandMadecarpets

Handmadecarpetsaretraditionallymoreexpensivethanthosemadebymachines.Thoughthere are several carpetmaking
methods, including braiding, hand tying (or hand knotting), hooking, shearing and tufting, the most common of these are

braidingandhandknotting.
Braided carpets are done by connecting or tying strips of fabrics together. Hand tying or handknotting are usually done on
Magazine
rugs. Countries that are known to produce beautifully crafted handknotted rugs include Spain, Portugal, India, Pakistan,
Books
Turkey,AfghanistanandJapan(amongothers).HandknottedrugsaredescendantsofOrientalRugsandcanbemadeinany
shape,size,colouredordesign.
Wallpaper Process

ScreenSaver Theprocessthatcreatesahandmade/handknottedcarpetcanbeexplainedasunder:

Videos Woolsorting&Washing
Wool is either imported or is bought from nearby markets and is carefully sorted to pick out
unwanted particles. Wool often carries dust, grease which is removed by washing it thoroughly
andisthensundriedfortwothreedays.
TheTibetan wool has a strong good fibre length is imported in scoured form, good lustre and a
highresilientvalue.TheNewZealandwoolisof36micron,100mmbarblengthandisidentified
as type 128. British wool meeting regulatory standards have also started being available in the
market.

Carding
Thecardingprocessallowsthefibrestandtoflowsmoothlywhenspinning.Thisisalsothe
stageforblendingdifferentwoolsandtoascertaintheratioofdifferentorigins.Traditionally,
cardingwasperformedbyhandandmachinecardingwasintroducedwhentheindustrygrew.
Howeverhandcardedproductisstillavailableifacustomersodesires.


Spinning
Thecardedwoolisspunintoyarnbyusingacharkhaoraspinningwheel.Thethicknessofthe
yarndependsonthequalityofthecarpetandgenerallya3plyyarnisused.


Dyeing
The traditional pot dyeing method has been largely replaced by machine dyeing in closed
Chambers. Dyes containing harmful substances such asAZO are banned and dyestuffs from
renowned international manufacturers are used. These dyes have a high degree of fastness.
Depending on the weather, the dyed yarn has to be dried in the sunlight for one to three days.
Potdyeingandvegetable(natural)dyeingarestillbeingusedbysomemanufacturers.


CarpetKnotting
Knotting is an art. Weavers who weave on a regular basis have a very good speed in knotting.
They tend to develop this speed over a span of time. One or more weavers work on a loom

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5/9/2016 CarpetManufacturingProcessProcessofHandMadecarpets
depending on the size of the carpet. Each weaver makes individual knots row after row. The
designs are chartered out on a graph and a map reader or another weaver instructs the graphic
designstotheonesknottingthecarpet.Thedyedyarnismadeintoballsandscissors,ironrod,
levers,combbeatersareusedastools.


Trimming

Thefinishedcarpetistakenofffromtheloomandthedesigns&patternsaretrimmedby
scissors.


WashingandDrying
Thetrimmedcarpetiswashedwiththefreshwater&chemicals.Thewashedcarpetisdriedin
thesunlightuptofourorfivedays.

FinalTouches
Thedriedcarpetsaregivenfinaltouchesbyretrimmingandstretching,whereevernecessary.
Thepurposeistobringthefabricwoveninlevelatthesurface.

Packing
Allwashedcarpetsarerolledandwrappedinpolythenesheetandissealedateachend.Again,
itiswrappedinHessianclothandsewn.Generally,around14m2arepackedineachbale.

Payment
Exportproceedsmustbereceivedthroughanirrevocableletterofcredit(L/C)oradvancepayment.


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