How a rug is made from design to delivery!

15 May 2020

What Design?

So you have decided you need a rug! What next? There are hundreds of options available to you but nothing is’ just right’. This is not the end of your journey but rather the beginning of something special - a bespoke custom rug made to your exact requirements.

It may be that you have seen a design you like but your size and colour options are not available or you have something very specific in mind - either way we can work with you to create a rug in the size and colours of your choosing.


Deciding on colours, fibre and construction.

Once you have decided on the design the fun begins - choosing your colour scheme. With over 1200 colours to choose from we can guarantee to find the perfect solution. Some designs require just two or three colours and others can be far more complicated but neither is an issue. With years of experience our consultants are well versed in the art of colour and tone selection and will help at every step of the way.

Based on your design selection we will advise on the best fibres (wool, silk or a combination of both) and the best method of construction (hand knotted, handwoven or tufted). Many factors can influence this choice but we're here to help and advise. Once this has been agreed we can move on to the next stage.


Drawings

Now to the more visual aspect of the journey - the drawings. To assist you in visualising the final product our highly qualified designers will create a PDF image of the rug showing scale and colour placement. This drawing can be adjusted as many times as required until you are happy and comfortable with the result.


Finalising Order

Having now chosen the design, selected the colours and settled on the final layout it is time to proceed to production. On payment of the deposit our highly skilled artisans can get to work doing what they do best - creating a rug that is Crafted for Life!


Dying the wool/fibre

Working from the drawing created and with access to the same colour selections as you viewed during the process the mill will now begin to dye the yarn. The dye is prepared by hand and then the chosen yarn is dyed and dried in the open air following a process that has not changed for years.

Washing the yarn

Spinning the yarn


Preparing the loom

While the yarn is being dyed the loom will be prepared to begin production. Stringing the loom is a detailed and time consuming process that requires great skill and attention to detail.


Weaving the rug

The weavers are assigned to your rug and will work from start to finish to ensure consistency throughout. The number of weavers per rug will be determined by the size of the rug but usually two will work side by side for the duration of the process.

Weaving equipment.


Finishing

Once off the loom the rug passes to the ‘finishers’ who are responsible for washing, trimming, stretching and drying the rug. All these processes are carried out by hand.

Washing the finished rug.

Packing & transit

To ensure your custom rug arrives in pristine condition a great deal of attention is paid to the packing process. The rug is tightly rolled and wrapped, marked with the individual code relating to the product and dispatched to our transit hub. The majority of our rugs are sent by air freight but on certain occasions, due to size, they will transit by sea. Whichever method is required we do our utmost to minimise delays and get your rug to you as soon as possible!


Underluxe - rug underlay

Dependent on the floor that your rug will rest on we recommend using an underlay to prevent the rug from moving. Your consultant will be able to advise and quote you on this option. This is something you can decide upon at the time of purchase or after you have received the rug.


Delivery

The final journey - the rug moves on to it’s forever home. After months of planning and weaving you now get to see your creation bringing life and colour to your home! We recommend our VIP service as our team will unpack, roll out the rug, move the furniture around to ensure your rug fits perfectly, then we remove the rubbish. Please discuss with your consultant to find out if this service is available in your area.

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