Rug Production

MAT – Rug Weaving Process



Step 1: Turn Wool into Yarn
The process of making a wool rug begins when unprocessed wool arrives at the factory in large bales. The wool is then separated by hand to remove sticks and break up clumps. Next, the wool is fed into a machine that separates and pulls the wool into individual strands. The wool is then spun into yarn. The yarn spinning process occurs over many types of machines until the yarn becomes twisted and strong enough.


Step 2: Wash Yarn

Before the yarn is dyed, it is first cleaned. Yarn is submerged into a detergent bath, and then wrung out several times before moving to the next phase of washing. The yarn is washed again in clean water to remove all remnants of detergent.

Wash Yarn


Step 3: Design Drawing

After the design is completed, it will then be enlarged to be the blue print and marked with colors in different columns for the weavers to follow.
Design Drawing


Step 4: Dyeing the Yarn

Dyes are created using a very precise combination of colors to produce the exact desired hue. Yarn is hung onto a large rack and submerged into the dye. The dye is heated to a near-boiling temperature for a predetermined amount of time. The amount of time is based on the color, the type of dye and darkness desired. Once dyed, the yarn is placed outside into the sunlight until it is completely dry.

Dying the Yarn


Step 5: Warp Hanging

Warps are fixed on the loom rack, almost like a standing frame which consists of 4 bars. The warps will be looped tightly between the top bar and the bottom one. The density of the warps is the key to the quality of the carpet and with more warps, the design looks more clear and vivid and accordingly, this requires more work.
Warp Hanging


Step 6: Weaving

There are two primary ways to weave a handmade rug: hand knotting and hand tufting. When hand knotting rugs, the weaver knots a continuous strand of yarn onto itself. When hand tufting rugs, the weaver uses a tool to push the yarn back and forth through a rug backing. For both types of rugs, a rug map, cartoon or talim is used to follow the design and color scheme of the rug. Typically, two weavers will work on one rug together and use a scaffolding system to raise and lower themselves along the entire length of the rug.



Step 7: Shearing and Trimming

A special machine is used to shave and level the rug across its entire width and length. This process also brings out the details of the weave and bold colors. Next, the design of the rug is defined using a steel spike to separate the pattern and colors.
Shearing and Trimming


Step 8: Washing

Again, the entire rug is washed to remove all remaining detergent, dirt and yarn particles. The rug is laid flat on the ground, then fresh water is poured over it. The rug washers then use a wood plank, sharpened on one edge, to force the water through the rug pile. This removes impurities picked up during the creation process.



Step 9: Drying

The rug then lies in the sunlight until it is completely dry or kept in a special drying chamber during the wintertime until it is completely dry.


Step 10: Stretching

The next step is to stretch the finished rug. The rug is stretched over the wooden panels to flatten the wrinkles and to ensure the rug lays properly on the floor.



Step 11: Final Finishing

A tufted rug is always finished with a backing cloth. This is done in two stages. First a think net, covered with high quality latex. Thereafter, a backing cloth is attached, which forms the underside of the rug. The quality of our latex complies with directives of IWS (International Wool Secretariat) directives and provides excellent durability. All sewing of edges, pile work and embossing is done by hand.

Final Finishing


Step 12: Packing

Lastly, the rug is rolled, packaged and shipped for sale.