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Processes Leading to Weaving
Import of Wool and Silk: We import our own raw materials from around the world. The wool used in our double knot product lines is imported directly from New Zealand and is pure worsted wool. We use hand spun Ghazni wool for our Peshawar Chobi product line, which gives it an antique and decorative look, like no other product from that region. Silk used in our Royal silk collection is imported from China of the finest quality to compliment the highest quality worsted wool used in its manufacturing. |
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Scouring: raw wool is received in bundles and is very greasy. So in this process a textile machine consisting of a spiked drum revolving inside a chamber fitted internally with spikes, is used to open and clean unprocessed wool. |
Spinning: machines are used for spinning wool, by means of a large number of spindles revolving simultaneously to draw out and twist (fibers) into different yarn counts into two ply and three ply as per our requirements for our product lines. |
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Dyeing: the color is imparted to our yarn by two different dyeing techniques, hand dyeing and machine dyeing. Hand dyeing techniques, along with vegetable dyes are used to give the yarn the texture and look of an antique rug in weaving of our Peshawar product line. We use the state of the art machinery and dyes for our bulk dyeing of our worsted product lines to give a new and permanent color. |
Weaving: There are many different weaving techniques that are used in manufacturing these beautiful hand made rugs and to achieve textures of any kind. Persian, Turkmen (Flat weave) and Turkish knots are some of many weaving techniques used by interlacing the yarns and silks of the weft and the warp on a loom to weave these magnificent carpets of different looks and texture. |
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Finishing Processes:
Once the rug comes of the loom it goes through a rigorous detailed process of finishing for its final inspection before packing!
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Washing: This is a three fold process where the back of the rug is burnt first in order to get rid of all the extra wool that is stuck to it over the months, during the weaving process. Then the rug is washed with compound materials, which make the permanent dyes stead fast for the remaining life of the rug. In the last leg of washing, it is shampooed and washed to give it the gleaming look that you desire. |
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Shearing: This is one of the most important and delicate processes in the finishing of the rug. It requires a lot of time and consistency because it is another one of those processes that can only be done by hand and there is no other alternative. The Shearer takes of the extra wool and gives the designs and colors the definition and clarity that it deserves as a hand made rug. |
Stretching: This is the last process where the rugs are nailed down to wooden platforms out in the sun for stretching, in case they have become crocked because of going through all these different procedures or even being on the loom for months while being woven |
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Final inspection before packing!
A company executive goes through a meticulous inspection of each and every rug with the designers to make sure the rug is made to order with accurate design and color details.
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