RUGS MAKING PROCESS
Hand-made carpets are traditionally more expensive than those made by machines. Though there are several carpet-making methods, including braiding, hand tying (or hand knotting), hooking, shearing and tufting, the most common of these are braiding and hand knotting.
The process of making our hand-made rugs operates on a centralised model, supported by comprehensive quality checks along the way. With this approach, we are able to work with and support specialist artisans, but ensure the highest quality in the end results.
The process of making our hand-made rugs operates on a centralised model, supported by comprehensive quality checks along the way. With this approach, we are able to work with and support specialist artisans, but ensure the highest quality in the end results.
RAW MATERIAL SELECTION
The best Flooring India Co. certified yarns, and natural raw materials are sourced and processed In-house in the FI factory premises.
CARDING, SPINNING & HANKS
The carding process allows the fiber stand to flow smoothly when spinning. This is also the stage for blending different wools and to ascertain the ratio of different origins. The carded wool is spun into yarn by using a charkha or a spinning wheel. The thickness of the yarn depends on the quality of the carpet and generally a 3 ply yarn is used.
Raw Wool, Poly, Viscose is cleaned and then spun into yarn with our most ancient techniques.
Raw Wool, Poly, Viscose is cleaned and then spun into yarn with our most ancient techniques.
DYEING/PROCESSING
Flooring India has its own Dyeing and processing house and dyes to over 3000 colors.
The traditional pot dyeing method has been largely replaced by machine dyeing in closed Chambers. Dyes containing harmful substances such as Flooring India are banned and dye-stuffs 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. Pot dyeing and vegetable (Natural) dyeing are still being used by some manufacturers.
The traditional pot dyeing method has been largely replaced by machine dyeing in closed Chambers. Dyes containing harmful substances such as Flooring India are banned and dye-stuffs 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. Pot dyeing and vegetable (Natural) dyeing are still being used by some manufacturers.
WEAVING/TUFTING
This method differs slightly from other weaving techniques as the pile is incorporated by hand with a pistol-shaped device. The pattern design is laid out on cotton fabric, which is then stretched over a frame. The tufting gun is used to punch the yarn through the fabric and is fastened to a latex base. The yarn is then cut and shaved to ensure equal height. In the case of rugs with different height volumes, the surfaces are cut by hand with special angled scissors. This technique allows the skilled artisans to create curved patterns and pile of different heights and densities.
A hand tufted carpet is manufactured utilizing a tufting gun with needles mounted in the front. The production process is conducted by operating the machine by hands. The tufted gun employed to create artistic floor pieces looks like a modern drilling machine that shoots soft and lustrous yarns into base. The carpet is produced on a frame which is laced up with a cotton foundation with the imprint of the design on it. Due to the set mechanism the yarn is shot and pulled back on the surface.
A hand tufted carpet is manufactured utilizing a tufting gun with needles mounted in the front. The production process is conducted by operating the machine by hands. The tufted gun employed to create artistic floor pieces looks like a modern drilling machine that shoots soft and lustrous yarns into base. The carpet is produced on a frame which is laced up with a cotton foundation with the imprint of the design on it. Due to the set mechanism the yarn is shot and pulled back on the surface.
FINISHING
Finishing is the final step of the manufacturing process that gives the carpets the final desirable characteristics, including enhanced appearance and perfection. This is one of the hardest process, and the most important process, because it includes the cleaning of uneven threads, and final check is done, giving it a clean, luxurious and even look, so that the life of the carpet is not decreased, and it gives that wow factor in the rug. The completed rugs are evened out, trimmed and prepared for export.
FINISHED PRODUCT
The dried carpets are given final touches by re-trimming and stretching, where ever necessary. The purpose is to bring the fabric woven in level at the surface.Then The finished rug is purchased by a customer to transform there living spaces.
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