Carpet Manufacturing Process
Wool is the basic raw material of carpet manufacturing. Generally the wool imported from Tibet is in raw form. It requires washing and is followed by sun drying for some days. Then these wools are sorted out and only fine particles are then sent to the carding house where the further processing is carried out. raw wool.
Spinning is the next process where the carded wool is spun into yarn using Spinning wheels. At this stage the thickness and thinness of yarns are ascertained upon which the quality of carpet is based. Generally 3 ply of yarn is used to weave the carpets spinning.
It is a stage where the yarns are given colors and shades. Some use traditional pot dyeing system and some use large machine dyeing. Dyeing also differs from chemical to vegetable. The use of high quality dyes give long lasting colors and are also eco friendly. Once the yarns are colored, they are then dried for 1-3 days after which the yarns are rolled into ball for ease while weaving.
Under the supervision of highly skilled carpet experts, the weaving process takes place. The size of carpet depends upon the size of the loom and the number of weavers engaged in the loom. Each loom is provided with a plotted graph to give carpet the desired design. Scissors, iron rod, levers and comb beaters are used as tools while weaving.
After the carpets are finished, they are taken out off the loom and then designs and patterns are curved with scissors. Trimming of designs gives carpet a vibrant look which separates the background color and pattern color distinctively.
Washing is another important stage of the manufacturing process. Chemicals used during wash give carpets high shine. There are different kinds of wash such as Antique Wash where the proportion of chemical used is maximum and some prefer Normal wash or Light wash. Drying of carpet is followed after the wash process is completed. Washed carpets are then dried in sunlight. Normally it takes around 2-3 days to dry and sometimes even longer depending upon the climatic condition.
After the carpets are fully washed and dried, they are inserted into square sized metal frames. All the edges of carpets are hooked from corners to corners with the metallic frames. Stretching brings carpet back into its normal or more or less desired size.
After the carpets are stretched, they are given finishing touch by cleaning-up and light trimming. Here, proper color, proper size and proper design are rechecked if they are as per the instruction or not. The manufacturing process concludes here.
The finished carpets are ready to be delivered. The carpets are rolled and then wrapped into round polythene sheet sealed at each end to prevent from moist and liquid. The outer part is wrapped by Hessian cloth and then sewn. The name and address of both the purchasing and selling parties are labeled outside the cloth. The bales are then given the number. Finally the carpets are ready for shipment.
The export of carpets requires certain custom clearance formalities. Hence, L/C (Letter of Credit) or Certificate of Advance Payment in any convertible currency from the purchasing party is required during export proceeds. As any other rugs suppliers, we too charge 50% advance payment after confirmation of order to start the work and remaining 50% amount after completion of work right before the shipment.