Production - Soorya Carpets

Production Process

Carpet making is an ancient traditional craft. It involves great craftsmanship and certain level of expertise on the part of the weaver. Although some carpets manufacturers may use some special weaving techniques, the principles of manufacturing hand-knotted carpet from designing to finishing are almost the same throughout the world.

Explore the Production process

Step 1: Sorting

Sorting of raw wool to pick out foreign materials and separate them based on their different natural color.

Step 2: Washing

Washing the sorted wool in warm water to clean it.

Step 3: Wool carding or combing

Wool carding or combing the wool using special traditional steel and wooden handmade comb to untangle fibers and remove impurities if any. In the process, fibers are opened and separated and each fiber is set in a straight and parallel position, and all foreign particles removed. This process also helps achieve better blending. Carding is either done manually or by machines.

Step 4: Spinning

Spinning the wool into a yarn in desired thickness using traditional wooden spinning wheel called ‘charkha’ in Nepali. Spinning involves drawing and twisting the wool fibers into yarns. The average length of a fiber should be 4″ to 6″ to spin the ideal yarn for carpet weaving. Traditionally, wool is spun by hand. However, machines are also being used for this process.

Step 5: Dyeing

Dyeing of the yarns in different colors of vegetable dyes or chemical dyes in a big pot with a wheel burning wooden or gas stove underneath.

Step 6: Weaving

Weaving of carpet in vertical loom by hand using traditional tools like scissors, iron-rod, levers, comb beater, iron hammer etc. The graph of design in 1:1 scale is followed while weaving. The woolen yarn is tied with two warp threads at different positions with the help of a weaving rod. This process is continued breadth-wise from left to right. The cotton weft is then inserted in between the warp thread alternatively. It is then beaten with an iron hammer and the wool around the iron-weaving rod is cut with a blade. Thus, a woolen pile is formed. The process continues until is entire carpet is woven. This process involves skill and craftsmanship.

Step 7: Clipping

Clipping of the woven carpet using traditional big size scissor called ‘khapsi’ in order to smoothen the level of pile and give shiny even surface texture.

Step 8: Washing

Washing the finished carpet with natural soap or environment friendly chemicals to remove dirt and restore the original shine of the wool.

Step 9: Drying

Drying the carpet in direct sunlight for about 2-5 days depending on the size and thickness of carpet.

Step 10: Carving

Carving of the design edges by scissor for a detailed and luxurious look and to ensure perfect and clean design finish.

Step 11: Stretching

Stretching the carpets on all four sides using metal frames and hooks in order to maintain the perfect shape of the carpet.

Step 12: Finishing

Finishing and checking the carpet for the size, shape, surface, designs, stains, etc. Vacuuming is done to ensure there is no dust particles in the carpet.

Step 13: Labeling

Labeling the carpet with all necessary details regarding size, type, etc. and then Packing in roll with a transparent heavy duty plastic bag for delivery.