RUGS MAKING PROCESS
Hand-made carpets are traditionally more expensive than those made by machines. Though there are several carpet-making methods, including braiding, hand tying (or hand knotting), hooking, shearing and tufting, the most common of these are Tufting, braiding, weaving and hand knotting for Unique Carpets and Tufted for More affordable luxury rugs.
RAW MATERIAL SELECTION
At Flooring India Company, we take pride in our commitment to quality from start to finish. That's why we meticulously source and process the finest raw materials right in our own Raymons Group premises.
We handpick the best certified yarns and natural raw materials, ensuring that each component meets our rigorous standards for excellence. By controlling the entire process in-house, from sourcing to processing, we maintain complete control over the quality of our products.
Our facility is equipped with the latest technology and operated by skilled professionals who share our dedication to craftsmanship and precision. Every step of the processing journey is carefully managed to preserve the integrity of the materials and unlock their full potential.
When you choose Flooring India Company, you can trust that you're bringing home not just a beautiful product, but also a testament to our unwavering commitment to quality and authenticity.
We handpick the best certified yarns and natural raw materials, ensuring that each component meets our rigorous standards for excellence. By controlling the entire process in-house, from sourcing to processing, we maintain complete control over the quality of our products.
Our facility is equipped with the latest technology and operated by skilled professionals who share our dedication to craftsmanship and precision. Every step of the processing journey is carefully managed to preserve the integrity of the materials and unlock their full potential.
When you choose Flooring India Company, you can trust that you're bringing home not just a beautiful product, but also a testament to our unwavering commitment to quality and authenticity.
CARDING, SPINNING & HANKS for hand techniques.
The carding process allows the fiber stand to flow smoothly when spinning. This is also the stage for blending different wools and to ascertain the ratio of different origins. 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.
Raw Wool, Poly, Viscose is cleaned and then spun into yarn with our most ancient techniques. For poly the machines have moved to automatic Plying machines.
Raw Wool, Poly, Viscose is cleaned and then spun into yarn with our most ancient techniques. For poly the machines have moved to automatic Plying machines.
DYEING/PROCESSING
We have Our own Dyeing and processing facility and dyes to over 3000 colors.
The traditional pot dyeing method has been largely replaced by machine dyeing in closed Chambers. Dyes containing harmful substances are banned and chemical dyes are sourced from renowned certified international manufacturers. 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 but are not .
The traditional pot dyeing method has been largely replaced by machine dyeing in closed Chambers. Dyes containing harmful substances are banned and chemical dyes are sourced from renowned certified international manufacturers. 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 but are not .
WEAVING/TUFTING
This method differs slightly from other weaving techniques as the pile is incorporated by hand with a pistol-shaped device. The pattern design is laid out on cotton fabric, which is then stretched over a frame. The tufting gun is used to punch the yarn through the fabric and is fastened to a latex base. The yarn is then cut and shaved to ensure equal height. In the case of rugs with different height volumes, the surfaces are cut by hand with special angled scissors. This technique allows the skilled artisans to create curved patterns and pile of different heights and densities.
A hand tufted carpet is manufactured utilizing a tufting gun with needles mounted in the front. The production process is conducted by operating the machine by hands. The tufted gun employed to create artistic floor pieces looks like a modern drilling machine that shoots soft and lustrous yarns into base. The carpet is produced on a frame which is laced up with a cotton foundation with the imprint of the design on it. Due to the set mechanism the yarn is shot and pulled back on the surface.
A hand tufted carpet is manufactured utilizing a tufting gun with needles mounted in the front. The production process is conducted by operating the machine by hands. The tufted gun employed to create artistic floor pieces looks like a modern drilling machine that shoots soft and lustrous yarns into base. The carpet is produced on a frame which is laced up with a cotton foundation with the imprint of the design on it. Due to the set mechanism the yarn is shot and pulled back on the surface.
BACKING
Carpet backing is an important aspect of carpet manufacturing, providing stability, durability, and support to the carpet pile. There are several techniques used for carpet backing, including: we have inhouse Backing capabilities:-
- Primary Backing: This is the foundation of the carpet and is typically made from woven or non-woven synthetic materials such as polypropylene or polyester. The primary backing holds the carpet fibers in place during tufting.
- Secondary Backing: Also known as the secondary layer, this is applied to the back of the carpet after tufting. It adds strength, stability, and dimensional stability to the carpet. Secondary backings are often made from materials like latex, polypropylene, or PVC (polyvinyl chloride). They can be applied as a liquid, foam, or as a pre-made backing material.
- Fusion Bonding: In this technique, the primary and secondary backings are fused together using heat and pressure. This creates a strong bond between the two layers, enhancing the durability and stability of the carpet.
- Needle Punching: This method involves mechanically interlocking the fibers of the primary and secondary backings using barbed needles. Needle punching creates a dense, stable backing that is resistant to tearing and stretching.
- Hot Melt Backing: Also known as thermoplastic backing, this technique involves applying a hot melt adhesive to the primary backing and then attaching the secondary backing while the adhesive is still hot. Once cooled, the adhesive forms a strong bond between the two layers.
- Woven Backing: In some cases, particularly for high-end carpets, the backing may be woven using traditional weaving techniques. Woven backings can be made from natural fibers like cotton or jute, or synthetic materials like polypropylene.
FINISHING
Finishing is the crowning step in the journey of crafting exceptional rugs, where meticulous attention to detail transforms raw materials into works of art. It's not just the final touch; it's the defining moment that elevates a mere carpet into a masterpiece.
This crucial process encompasses a symphony of tasks aimed at refining every aspect of the rug. From tidying up uneven threads to ensuring impeccable cleanliness, each rug undergoes a thorough examination to guarantee flawless quality. This meticulous attention to detail not only enhances the rug's appearance but also extends its lifespan, ensuring it remains a cherished centerpiece for years to come.
At Flooring India Company, we understand that finishing isn't just about aesthetics; it's about infusing each rug with a sense of luxury and sophistication. Our skilled artisans devote themselves to achieving perfection, meticulously smoothing out imperfections, trimming edges, and meticulously preparing each rug for its journey to homes around the world.
When you choose one of our finished rugs, you're not just investing in a floor covering; you're bringing home a testament to unparalleled craftsmanship and unwavering dedication to quality. Let our rugs be the centerpiece of your space, adding that unmistakable 'wow' factor that only comes from the perfect finishing touch."
This crucial process encompasses a symphony of tasks aimed at refining every aspect of the rug. From tidying up uneven threads to ensuring impeccable cleanliness, each rug undergoes a thorough examination to guarantee flawless quality. This meticulous attention to detail not only enhances the rug's appearance but also extends its lifespan, ensuring it remains a cherished centerpiece for years to come.
At Flooring India Company, we understand that finishing isn't just about aesthetics; it's about infusing each rug with a sense of luxury and sophistication. Our skilled artisans devote themselves to achieving perfection, meticulously smoothing out imperfections, trimming edges, and meticulously preparing each rug for its journey to homes around the world.
When you choose one of our finished rugs, you're not just investing in a floor covering; you're bringing home a testament to unparalleled craftsmanship and unwavering dedication to quality. Let our rugs be the centerpiece of your space, adding that unmistakable 'wow' factor that only comes from the perfect finishing touch."
FINISHED PRODUCT
After the meticulous finishing process, each rug emerges as a true masterpiece, ready to grace your home with its beauty and elegance.
With every thread perfectly aligned and every imperfection expertly corrected, our rugs exude a sense of refinement and luxury that transforms any space they inhabit. From vibrant colors to intricate patterns, each rug is a testament to the skill and dedication of our artisans.
But our commitment to quality doesn't stop there. Before being sent off to their new homes, each rug undergoes a final inspection to ensure that it meets our rigorous standards of excellence. Only once it passes this last check of quality is it deemed ready for export.
Whether adorning the floors of a cozy living room or adding a touch of sophistication to a formal dining area, our rugs are more than just floor coverings; they're statements of style and craftsmanship. Bring home the perfect finishing touch for your space with a Flooring India Company rug, and experience the difference that true quality makes.
With every thread perfectly aligned and every imperfection expertly corrected, our rugs exude a sense of refinement and luxury that transforms any space they inhabit. From vibrant colors to intricate patterns, each rug is a testament to the skill and dedication of our artisans.
But our commitment to quality doesn't stop there. Before being sent off to their new homes, each rug undergoes a final inspection to ensure that it meets our rigorous standards of excellence. Only once it passes this last check of quality is it deemed ready for export.
Whether adorning the floors of a cozy living room or adding a touch of sophistication to a formal dining area, our rugs are more than just floor coverings; they're statements of style and craftsmanship. Bring home the perfect finishing touch for your space with a Flooring India Company rug, and experience the difference that true quality makes.
We Would Love to Have You Visit Soon!
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