Rug Manufacturing Guide
Three different methods in which a rug is manufactured
The process of manufacturing rugs matters a lot as it decides the durability, comfort, look, quality, etc. of the resulted rug. The rugs may be either handmade or machine produced, and the main manufacturing techniques used by the rug manufacturers include Hand-knotted, Hand-Tufted, Machine-made.
Methods of hand-knotting date back to thousands of years ago. This ancient art takes the help of a special wooden frame known as looms to weave by using the hands. At first, vertical thread (warp) is tied on to the loom, followed by the intertwining of horizontal threads (weft), knots are then tied on the vertical threads, which are then cut using a knife. An average weaver can tie about 10,000 knots in a day.
For this reason, the process takes a long time to finish, and it takes one month to make a rug. Natural fibers such as wool, cotton, etc. are used to make the rug. The products offer high quality and are highly expensive as the design of the back will be the same as the design of the front.
A tufting gun containing a needle at its front is used to punch in and out of the fabric (canvas) stretched on a frame. Tufting-gun is a hand-operated tool where wool is mostly used for tufting. Once finished, the rugs are removed from the fabric, and a liquid latex or glue is used to coat the backside that prevents the yarn from unraveling. When compared to hand-knotting, this method takes less time to create rugs. The design will be presented only on one side; the backside would be blank in tufted rugs.
A machine called ‘power loom’ is used to weave the rug, which is run by electricity and uses synthetic fibers to produce rugs. They are the quickest way and speed up the weaving process. Not much skill is required –when compared to Hand-knotted Rugs.