The main sections of a carpet’s design are first drafted on graph paper, with each cell in the graph representing one knot.
The vertical and horizontal lines drawn onto the graph divide the paper into square inches. Depending on the desired size and knots per square inch, the scale of the drawing and the graph paper used will vary.
After the draft design has been approved, the next step is to fill in colors using water-based paint. Generally, each color will represent a sample of dyed wool.
Remember that each box in the graph paper represents one knot in the carpet to be made. The designer must paint the design accordingly – two separate colors should not fall into the same box.
Next, the rug’s design and colors are encoded into a weaver’s language. The weaver will read the encoded language while weaving the rug as a pianist would read music. This ensures that the design and colors are adhered to as closely as possible. Generally, the designs for all city-made rugs are encoded in this manner.
While the rug’s design is being encoded, the appropriate wool is selected from Pak Persian Rugs’ stock of undyed wool. For example, an Agra rug will use handspun Ghazni wool (shown here), while a Mogul Kashan rug will use imported worsted wool, usually from New Zealand or Australia.
As mentioned earlier, the colors painted onto the graph paper of a design will represent particular samples of dyed wool. The samples are usually attached to the completed design.
The wool is then dyed in batches to match the samples by immersing it in a mixture of dye and boiling hot water in large vats. Before a large batch of wool is dyed, as shown here, usually smaller samples are dyed first to ensure a correct match in shade.
The color of the wool to ensure that it is dyed to the correct shade of red.The dyed wool is then hung outdoors to dry. Weather conditions can affect the dyeing process – a batch of wool dyed on a cold, cloudy day may have a different appearance to a batch of wool dyed on a warmer, sunny day.The dried wool is then spun on to smaller spools for use on the loom.
When the dyeing and encoding have been completed, the master-weaver is handed the materials and the rugs encoded design. He will then begin to weave the rug on the loom.
Each row of knots is should be packed tightly. This ensures that the size and quality of the rug remain true to the designed size and quality.
After the excess wool is burned off and the rug has been clipped, the rug is washed.
The soapy water (and burnt wool) is then removed using a specialized scraper.
The process is repeated several times to ensure that the rug is thoroughly clean and color-fast. The washing should be done in three times .In the final stages; fresh water is used to remove the soap completely.
when the rug have been washed, rugs are stretched and dried in the sun face-down, usually for 3-4 days it’s all depend upon the weather, if it is cloudy weather then it takes round about 1 week.
Nails are placed between the weft and warp of the Carpet to avoid damaging it. The purpose of nail is to place to straight the Rug.
When the rug has been completely stretched, the fringe is clipped and secured.
When the rug completed all the stages then they are ready to be shipped to showrooms and galleries.