Carpet Production Process
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Rugs Manufacturing Process
A Floor Covering which is made completely by human hands by Handknotting, Handtufting or Handweaving, in which handspun Yarn of natural fibers (most commonly wool or silk) is used, with individual character and design. 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.
Derived By: Carpet Export Promotion Council (CEPC) India
1 - Raw Wool
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 and is then sun-dried for two three days.
2 - Woll Scouring
It is the process of washing of Wool fibre. Wool fibre has lot of dust, dirt and the sticky oily material called Suint. Suint is the wax like material which comes out from sweat glands of Sheep. The fibre has to be washed with caustic to remove suint.
3 - Woolen Yarn Spinning
Spinning involves two steps Carding and Spinning- Carding is sometimes done by hand with help of carding brush or on carding rollers run by hand. The carded wool is spun into yarn by using a charkha or a spinning wheel.
4 - Yarn Dyeing
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.
5 - Yarn Opening Or Reeling
Reeling is a process that involves opening the bigger and loose lea and wrapping it into tightly wrapped bunch which is smaller in size
6 - Computer Aiding Designing (CAD)
When speaking about patterns and carpet manufacturing these are often divided into three categories; curvilinear, geometric and figural patterns. There are many frequent named patterns, we will mention a few of the most common ones.
7 - Raw Washing
It is done as the first wash to clean the carpet and for removal of dust and dirt or any stains on the carpet.
8 - Shearing
After carpet is washed the piles are cut to level them to same height. This is called Shearing.
9 - Side Binding
The sides of the carpet is bound by a separate thread which is a thick thread and often doubled. This gives additional strength to the carpet.
10 - Final Washing
The carpet is washed for the final time. Final washing provides it the required luster.
11 - Drying
In traditional setup dyeing is done under the sun, but many manufacturers have drying machine which can control the tempreature and moisture of the carpet.
12 - Stretching
Stretching is done to make the sides straight otherwise the carpet has some curved edges.
13 - Final Clipping
Final Clipping This is the finishing step in the manufacturing of carpet. The clipping is done with minute detailing.
14 - Packing And Bailing
After the carpet is finished, it is packed and bailed for exports.
