HAND TUFTED CARPETS

view all

CUT PILE CARPETS

view all

FLATWEAVES

view all

Our Hand Tufted Rugs Manufacturing Process

If You’re Curious About What Makes Us The Best Hand-Tufted Best Rugs Manufacturer For Rugs Markets Like The USA & The United Kingdom. Here’s Our 10 Steps Formula For Hand-Tufted Rugs Manufacturing.

Designing & Planning

The Manufacturing Process Of Our Export-Oriented Rugs Starts With The Designing Of The Rugs & Carpets. 1st Of All Our Team Of Experienced Designers and Best Rugs Manufacturer s Conceptualizes The Rug Design According To Your Exact Requirements. Then They Draw A Pattern, Colors, And Overall Look Of The Rug Using Software On Graph Paper.

After That, Our Team Of Experts Prepared And Placed A Large Size-Stencil Or Blueprint Of The Design On The Primary Backing Material. This Will Play A Part Of The Guide To The Craftsperson To Perfectly Follow The Pattern During The Tufting Process.

Material Selection & Dyeing

The 2nd Step Starts With The Material Or Yarn Selection For The Hand-Tufted Rugs Manufacturing. The Most Commonly Used Yarn In The Manufacturing Of Hand-Tufted Rugs Is Wool Due To Its Softness, Resilience, And Natural Properties. However, The Material Selection Depends On Your Choice & Decision. You Can Also Choose Silk, Cotton, Or Synthetic Fibers Like Nylon, Acrylic, Or Polyester.

After Material Selection, We Move Towards Dyeing And Dyed The Yarn According To Design Specification Using Synthetic And Natural Dyes. The Dyeing Process Of Yern Is Executed By Our Team Of Experts To Ensure The Consistent & Vibrant Look Of The Yarn. Then We Washed And Dried The Yarn Thoroughly.

Preparing The Frame For Primary Backing

We Placed Primary Backing On Sturdy Fabrics Like Canvas Or Cotton. We Tightly Stretched The Backing Fabric Over A Large Wooden Or Metal Frame For Primary Backing. The Backing Fabric Works As A Base Where The Yarns Are Tufted.

After That, We Traced The Rug Design On The Stretched Backing Fabric. This Backing Fabric Works As A Roadmap For Tufters During The Placement Of Different Textures And Colors.

Tufting Process

We Do Tufting By Using The Hand-Operated Gun To Insert Yarns Into The Backing Fabric. The Gun Forms The Loops On The Surface And Pushes The Yarns Through The Fabric. Our Expert Gun Operators Control The Depth And Length Of Each Tuft. Which Can Be Adjusted To Create Cut Piles And Loop Piles.

Cut Pile: For A Pulsh Finish, We Cut The Loops Immediately By Using A Tufting Gun And Creating Upright Piles That Feels Soft And Luxurious.

Loop Pile: The Loops Are Remain Uncut And Have A Textured Looped Surface That Visually Different And Durable.

Our Team Of Experienced Tufters Makes Sure To Steady Hand And Focus On Details To Ensure The Tufting Process According To Design Specifications. The Speed Of This Process Depends On Complexity And Design Of The Rug.

Securing The tufts

After Completing The Tufting Process, We Coated The Back Of The Rugs With Latex To Secure The Yarns. This Step Is Important To Save The Yarns From Slipping Over The Time. We Also Add A Secondary Backing To Secure The Tufts. Secondary Backing Is Usually Made Of Jute, Polyester, And Cotton Fabric To Apply Over The Adhesive Layer.The Secondary Backing Adds Strength, Durability, And A Finished Appearance To The Rug That Makes The Rug More Strong & Stable.

Trimming, Sculpting, & Finishing

We Trimmed a Pile To A Uniform Height Using Specialized Trimming Machines. Trimming Smooth Out The Surface And Making The Rugs Look More Polished And Well Defined.

Our Team Of Experienced Craftspersons Use Clippers To Sculpt Patterns Into The Rugs To Add Depth And Texture To The Rugs. This Technique is Commonly Used In Floral And Geometric Designs. Where Some Areas Are Sculpted To Enhance The Visual Appeal.

Washing & Drying

We Washed The Rugs Carefully To Remove The Residual Dirt, Dye, Or Latex. This Process Also Softens The Fibers And Enhances The Colors To Give The Rug A Fresh And Vibrant Look.

After Thoroughly Washing We Stretched And Dried The Fabric In Our Environment Controlled Facility To Maintain Its Shape And Save From Shrinkage.

Quality Control & Inspection

Being As The Best Rugs Manufacturer We Implement Strict Quality Controls At Our Manufacturing Facility. Where Each Rugs & Carpets Goes Through Strict Quality Controls And Quality Checks On Each Step. We Perform This Process To Identify And Correct Flaws Like Pile Height, Loose Yarns, And Colors.

If Our Inspection Team Found Any Issue Then Our Experienced Team Repaired The Rug Manually. Rug Repair Process May Includes Re-Tufting & Adjusting The Trimming Areas To Achieve The Desire Look.

Edging & Binding

In This Step, We Finish The Edges Of The Rug To Avoid Fraying. Binding Secures The Edges To Provide A Clean And Durable Finish. After Edging And Binding, We Labeled The Rugs With Your Given Details Including Material Composition, Size, And Care Instructions.

Packing & Finishing

We Rolled And Wrapped The Finished Rugs In Protective Material To Pack And Secure The Rugs From Damaging During Transit. After Packaging, We Shipped The Rugs And Make Sure That They Arrive To You In Perfect Condition.