Hand knotted carpets take a long time to get ready, and a lot of effort is expended in the nine different processes a hand-knotted carpet goes through:
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 and grease, which are removed by washing it thoroughly. It is then sun-dried for two to three days. Tibetan wool has a strong, good fiber length and is imported in scoured form. It has a good luster and a highly resilient value. New Zealand wool is of 36 microns, 100 mm barb length and is identified as type 128. British wool meeting regulatory standards has also become available in the market. Wool from the Middle East has a tremendously soft texture and a shine to it.
The carding process allows the fiber strand to flow smoothly when spinning. This is also the stage for blending different wools and for ascertaining the ratio of wools 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. For different qualities, the expert decides which wool is suitable for what type of carpet.
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 natural, vegetable-dyeing are still being used for some qualities.
Knotting is an art. Weavers who weave on a regular basis have 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 charted out on a graph, and a map-reader, or they are recorded in a symbolic language called Talim. Talim is a special coded language that only a few specialized weavers can understand, and our special carpets like Huwa Hu, Sandal Mubarik Rug, and our fine quality Dhikr carpets are made using Talim.
The finished carpet is taken off of the loom, and the designs and patterns are trimmed by scissors to make the wool pile equal all the way through.
Washing and Drying
The trimmed carpet is washed with fresh water and chemicals. Then, the washed carpet is dried in the sunlight for up to four or five days. Special carpets, which hold sanctity due to their designs, are given special care. All the possible steps are taken to make sure no one walks over these rugs while washing. Usually, they are placed at some high point and are washed with extreme care.
The dried carpets are given final touches through a process of re-trimming and stretching, wherever necessary. The purpose of this is to bring the fabric woven in level at the surface.
All washed carpets are rolled and wrapped and are sent to their destination.
The nine step process described here takes from three months to about a year sometimes. The time varies according to the quality and size of the carpet.
From The Blog
“Assalamu 'alaikum warahmatullah , I pray you are well. Allahu akbar.... it's beyond words. I'm so honored and pleased to have this. I really can't express it. Thank you so much, as well as whoever else was involved in making it. Alhamdulillah, washukrulillah..”
Sheikh Faraz Khan