The process that creates a hand-made/hand-knotted carpet can be explained as under:
Wool sorting & Washing
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.
The Tibetan wool has a strong good fibre length
is imported in scoured form, good luster and a
high resilient value. The New Zealand wool is of
36 micron, 100 mm barb length and is identified
as type 128. British wool meeting regulatory
standards have also started being available in
The carding process allows the fibre stand to
flow smoothly when spinning. This is also the
stage for blending different wools and to
ascertain the ratio of different origins.
Traditionally, carding was performed by hand and
machine carding was introduced when the industry
grew. However hand carded product is still
available if a customer so desires.
The carded wool is spun into yarn by using a
charkha or a spinning wheel. The thickness of
the yarn depends on the quality of the carpet
and generally a 3 ply yarn is used.
The traditional pot dyeing method has been
largely replaced by machine dyeing in closed
Chambers. Dyes containing harmful substances
such as AZO are banned and dye-stuffs from
renowned international manufacturers are used.
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.
Knotting is an art. Weavers who weave on a
regular basis have a very good speed in
knotting. They tend to develop this speed over a
span of time. One or more weavers work on a loom
depending on the size of the carpet. Each weaver
makes individual knots row after row. The
designs are chartered out on a graph and a map
reader or another weaver instructs the graphic
designs to the ones knotting the carpet. The
dyed yarn is made into balls and scissors, iron
rod, levers, comb beaters are used as tools.
The finished carpet is taken off from the loom
and the designs & patterns are trimmed by
Washing and Drying
The trimmed carpet is washed with the fresh
water & chemicals. The washed carpet is dried in
the sunlight up to four or five days.
The dried carpets are given final touches by
re-trimming and stretching, where ever
necessary. The purpose is to bring the fabric
woven in level at the surface.
All washed carpets are rolled and wrapped in
polythene sheet and is sealed at each end.
Again, it is wrapped in Hessian cloth and sewn.
Generally, around 14m2 are packed in each bale.
Export proceeds must be received through an
irrevocable letter of credit (L/C) or advance