How we make a hand knotted rug.
Unprocessed wool arrives at the factory in large bales. The wool is then separated by hand to remove sticks and break up clumps. The wool is then spun into yarn by hand which is called hand spun. The good thing about Afghan Rugs that all are of Hand Spun which is much better then mill spun.
Once all material is ready, then we have to supply our weavers with the design and required yarn.
Before the yarn is dyed, it is first cleaned. Wool often carries dust, grease which is removed by washing it thoroughly. Yarn is submerged into a detergent bath, and then wrung out several times before moving to the next phase of washing. The yarn is washed again in clean water to remove all remnants of detergent and it is then sun dried for two to three days.
When the rugs leave the loom, they are extremely thick, having had only a preliminary clipping, and — no getting around it — they look brand new. They still must be clipped and finished. Clipping is especially hard, though, because you have chosen to use handspun wool. The traditional method of clipping hand-spun wool is to clip it in stages: up to six separate clippings with washing in between. The easy way to handle this problem is to wash the rugs in a kind of conditioner that untangles the fibers of hand-spun wool. With this treatment, the rugs need only be clipped twice, with one intermediate washing. You believe that the conditioning process harms the wool, and you decide that the rugs must be clipped without conditioner at a far greater cost. None of the washing involves chemicals except soap because you are unwilling to compromise the wool.
Dyes are created using a very precise combination of colors to produce the exact desired hue. Yarn is hung onto a large rack and submerged into the dye. The dye is heated to a near-boiling temperature for a predetermined amount of time. The amount of time is based on the color, the type of dye and darkness desired. Once dyed, the yarn is placed outside into the sunlight until it is completely dry.
One of the most important part of making a rug is finishing. Once finished from Washing, the rugs come for final touches, this includes stretching, clipping small threads, binding missing sides and etc.