The materials that make up a rug have an enormous effect on its color, texture and overall quality. The raw material preparation, wool ageing and dyeing process are all very important factors. Initially, the fibers of the wool, silk or cotton must be washed and 'carded' to untangle the fibres and create long lengths of 'yarn'. These are then dyed using either natural or chemical dyes.
Many people are fascinated by the intricate and ancient weaving process of creating a rug. Although different cultures have developed important rug-making traditions, the basics of a fine-quality carpet have remained relatively unchanged for centuries (and even millennia). Regardless of where a rug is made, the same basic steps are involved in its construction. The primary foundation of a rug is the loom, which is a frame that supports strands of wool that create the pile. The loom consists of two vertical beams, usually of wood or metal and two horizontal beams that are similar in construction. The distance between the vertical and horizontal beams determines the rug’s width. Warp threads, which are usually cotton, are strung between the vertical and horizontal beams. The warp threads are then beaten with a bitter made of steel to ensure that they are tightly woven together. The wool is then carded, which is a process of opening and separating the fibres so that they are set in a straight or parallel position. This also helps in removing foreign materials like sand or vegetable matter from the yarn. Effective carding allows the fibres to become softer and easier to spin. Once the yarn has been spun into a rug, it is passed through the warps and beaten with the bitter to create a densely woven foundation. This is a very time-consuming process that requires a high degree of skill and patience. It is the process that makes a rug look supple and feel silky smooth to the touch. During this stage of the manufacturing process, knot density is measured to assess the quality of the finished product. The higher the knot density, the more expensive the rug will be. Once the rug is complete, it is then trimmed with sharp scissors to eliminate uneven fibers. A secondary backing is then attached to the rug, which strengthens it.
The dyeing procedure is the process of coloring the yarn for hand-knotted and tufted rugs. It is a complex procedure that requires the right knowledge and accuracy. Otherwise, the resulting rug may not give you the desired appearance. Generally, the dyeing is done after the weaving has been finished. Dyes can be forced into the fiber by immersion (piece or back dyeing) or printed on the fabric, using screen printing, roller or ink jet. Printed rugs are more color stable than those which are dyed before the piece is woven together, but are not as durable as a rug or carpet that has been dyed in the wool and fixed with heat during the dying process. Once the dye has been applied, the wool is twisted to form the desired yarn. This is traditionally done by hand, using a charkha or rudimentary spinning wheel. The twisting allows the yarn to be dyed and provides an even consistency of thread thickness throughout the entire rug or carpet. The knot density of the wool is also measured at this stage, often as kpsi, or knots per square inch or decimeter. The higher the kpsi, the more expensive the rug or carpet will be. There are two kinds of dyes used in the manufacture of rugs and carpets, natural and chemical. Natural dyes provide a more muted and natural palette, while chemical dyes can be brighter, more vivid and more colorful. It is not uncommon for a rug to experience dye bleeding after it has been washed. This can be caused by a number of reasons, such as improper cleaning or the residual dirt and oils left behind from the dyeing process.
The yarn for each rug is dyed in over 3000 colours. During this process, the warp and weft threads are immersed into boiling hot vats of dye, wrapped in cloth to prevent the yarn from getting wet and are kept for over a week to embed the desired colour. After the dyeing process is complete, artisan hand shears the rug. This is done to ensure that the pile height remains consistent throughout the entire carpet. It also makes it easier for artisan to correct design mistakes or make changes in the pattern. Khadi Gultarash, or Put Gultarash as it is known in the US, refers to the carving of the design into the rug. It is a technique used to give the rug a high and low effect and can be seen on most of our rugs. During this step, an artisan keeps the scissors straight and goes over the rug line by line to remove or snip extra strands of cotton that are interlocked. This is a time consuming process that requires great precision.
The Gultarash rug weaving process is an artistry that has garnered global recognition, attracting collectors and enthusiasts. The intricate patterns and motifs of these carpets tell the story of the region’s rich culture and history. It takes months and even years for artisans to weave a single masterpiece, with the weavers putting their hearts into each stitch. The Put Gultarash process is one of the final steps in a carpet’s production, which ensures the highest quality and accuracy. Unlike other flatweaves, such as a Dhurrie or Kilim, the rugs made by Gultarash weavers are woven using interlocking warp and weft threads. This technique allows artisans to incorporate a wide range of designs, patterns, and colors in their creations. In the Put Gultarash step, an artisan brushes over the entire rug, sharpening its design by shearing and snipping extra strands of yarn. The artisan also goes over the pattern, separating and cleaning each knot to perfect its look. This is a crucial step in the carpet’s manufacturing, as it gives its final form and shape. The Ambiente has taken an innovative approach to this craft by employing a people-centric business model that conserves ancestral knowledge while connecting rural craftsmanship with global consumers. They’re committed to providing training and resources to their weavers, helping them grow professionally and enhancing their manual skills. As a result, they have an 85 per cent female rug manufacturer workforce across their network of over 40,000 weavers crisscrossing India. This women-led workforce is an example of the company’s dedication to sustainable manufacturing and empowering women in traditionally conservative communities.
A rug is a highly-prized textile, the product of a huge investment in time and labour. Consequently, the final inspection process for rugs is very thorough. It involves examining the rug’s quality, colourfastness, durability, and size accuracy. A rug that passes this rigorous inspection is ready to be rolled up for pick-up or delivery. The rug’s fabric is then sheared to remove the excess fibres and produce a smooth carpet face. The rug is also washed to ensure that it is clean and free of contaminants. After the rug is washed, it is hung to dry in a controlled environment to prevent unnatural shrinkage. It is then combed with soft groomers made specifically for rugs. This process helps to eliminate surface soils and makes the rug more lustrous. Saxony is a cut-loop carpet with a low pile (about 9 mm). This type of rug features heatset, twisted yarns that create a hard closed yarn seal, resulting in superior resistance to foot marks and walkway formations. Multi-level cut-loop Saxony features different coloured yarns looped together to produce a pattern. This design is used where a small pattern cannot be produced with printing and where large contour distortions would occur. Frieze, or twisted, velour, is a densely-woven carpet that produces a very durable and functional flooring option. This type of carpet has a very strong tensile strength and offers better wear and tear than other types of tufted products. A flat weave rugs are woven on a flat loom and can be made in various materials. These rugs are very hard-wearing and easy to maintain. They are ideal for areas of heavy traffic and can be made in a range of colors and styles. These rugs are often used in children’s rooms because they are very resilient and provide good sound absorption. However, they are susceptible to mold and mildew which can release spores into the air and cause respiratory symptoms such as watery eyes, runny nose, congestion, and asthma.