Carpet/Rug Making Process:
Carpet/Rug manufacturing has been the traditional business of the villages in
the northern mountainous belt of Nepal . But commercial carpet manufacturing
began in Nepal along with the exodus of Tibetan refugees in Nepal, in 1959.
Though Nepalese were weaving carpets for generations, Europeans through
Swiss association for technical Assistance ( SATA) contributed in the
development of the carpet industry in Nepal through financial and technical
support to the Tibetan refugees, In the beginning it was started as a source of
living for the Tibetan refugees and the products were just the items for tourist
consumption. Gradually, it began to attract a consumer adored initiated, in
1964. From the first commercial shipment to Europe, particularly Switzerland.
Since then, it has transformed into a more value added, labor intensive
commodity and remains the most important export product in Nepal by abysmal
effort entrepreneurs with international vision.
Carpet production is manually done right from the beginning to the finishing
stage. The vital process include:
Wool sorting & washing:
Tibetan wool is sorted to pick out foreign materials & other forms of wool to
have stable product. It also needs normal washing to remove fat & wax from the
The wool is then dried in sunlight for two to three days. Wool obtained from the
third countries is generally obtained after scouring process hence it doesn't
need sorting & washing.
After the wool get dry, carding is performed by hand using two hand brush to
make the washed wool more soft to spun it by hand. This process is very vital
for to get natural texture on rug. . But the hand carding couldn't fulfill the
demand of expanding carpet industries. Hence machine carding is also
performing for larger supply of carded wool for spinning.
Wool spinning is done by hand charkha. The experienced Nepalese spinners
are capable of producing course as well as finer yarns for higher knots carpet.
Dyeing was carried out in huge copper vessels, a manual estimation of color
has been observe during this process which will result on natural texture of
uneven colors on yarn.
A vegetable dyes is also exists as per the requirement of clients. Beside this
machine dye is also available for huge commercial order requirements. With the
introduction of machine dyeing better fastness has been obtained. Also the use
of synthetic dyestuffs has provided a large scale of spectrum color. The yarn is
dried in the sunlight.
Carpet weaving is performed by hand using graphs & sketches. The carpet
weaving is a creative task which is performed by three or four laborers
according to the size of carpet. Carpet weaving is done with the help of yarn
balls, scissors, iron-rod, levers, comb beater, etc. Century old traditional
Tibetan double knotting system is applied for knotting.
The sharp design & pattern is carved out by scissors from the woven carpet.
The level of the pile is also made smooth according to the design.
Washing and drying:
Carpet is washed with fresh water using household chemicals to keep free of
germs and wipe out the gloomy appearance. The wash is perform by
experience labors by using a wooden plate called faruha, which should rub and
hit around the carpet to open the tied yarn which make the front and top of the
carpet more soft and smooth and it also bring the beautiful shine on finished
carpet. The carpet is then keep flat on direct sun light for 4- 5 days to make it
dry and to get the best shiny appearance, which we called natural dry, instead
of putting it on hitting chamber.
The carpet is given a final trimming of the unusual yarn which comes after
washing, In this case any error in the design & Pattern is trimmed and given the
final touch. A three dimensional look will be given to motifs to look it more
better. However the higher knots carpet kept untrimmed seeing the details and
busy motifs. However its still depend upon each individual client's requirement.
The carpet has to be stretched to bring into the original loom- stage size by
stretching. Stretching provides the good appearance of carpet if it is under
sized or twisted anywhere. Only the stretch carpet lay flat on floor.
Finally the carpet is packed with the environment friendly packing material. After
that the carpet is ready for export. Most of the Custom Order Carpet pack and
ship folded, not rolled. Only the bulk order package will be rolled for shipment.
Creation Exports Nepal
Tibetan area rugs