Archive for the ‘Kids Rugs’ Category

From the Sheep to the Rug

Friday, November 6th, 2009

Washing the Fleece

Sheep almost always live in the open air, and even the more primitive breeds no longer shed their wool at the end of the winter. This means that they get dirty – often VERY dirty – dusty, muddy and sweaty with lots of entangled bits and pieces. It must be such a relief to dash away from the shearer, free of all that weight, smell and heat. Rugs and carpets, however, be they modern or antique, smooth or shaggy, are expected to be pretty or smart colours and to lack that distinctive aroma that shouts ‘sheep!’

To bridge the gap, the first process towards your rug is scouring, which means washing and rinsing the wool to remove most of the impurities, from sweat to bits of twig. In some breeds (the very sweaty ones) this can reduce the weight of the fleece by up to 50%, but the wool usually used for Designerug rugs and carpets loses only about 25 – 30% of weight in this process – so you know that your shaggy rug may have come from a shaggy sheep, but at least it hasn’t come from a very smelly one!

Scouring, in the case of wool, means gently washing in a detergent mixture, then rinsing until it is free of dirt and detergent both. The wool is usually passed through a series of long, narrow tanks on a belt. Each tank is equipped with a set of gently moving paddles to keep the water moving without tangling the wool. The first tank contains the cleaning mixture, which rapidly becomes extremely dirty. After that, it is pressed through rollers to remove as much water as is possible without turning the whole thing into felt. Then the belt moves it along, in and out of rinsing baths, each rinse being followed by a further gentle pressing. By the fifth bath the cleaning materials have been washed out and the wool looks bright and clean, and shows a surprising range of shades, from palest cream to beige. Of course, there are also black sheep, but their wool is separated out before the scouring. The final process is drying and fluffing, which happens as the belt moves through an oven and the wool is dried with jets of very warm air. Now it is ready for the next stage – the spinning.

Spinning the Wool

Blending.  Ideally, all the spun wool will be a standard colour so the dyer will be able to judge quickly how to produce that puce you chose for your designerug pattern. Unfortunately the sheep are not too interested in that part of the job, and their coats vary over a surprising range, according to age, diet and specialized breeding.

The Blender is the man who sorts that problem out, judging by sight which bales of washed wool have to be dumped into the big blending bin (like an enormous mixing bowl, with paddles) to give an even-coloured yarn at the end. In the blending bin the wool is tossed and stirred to mix up all the different bales of wool, but carefully enough to avoid tangling them. This makes sure that there won’t be darker or lighter lengths in the final yarn. At the same time, a special oil is added to the wool to avoid what could be a dangerous build-up of static electricity as thee wool is processed (most of this oil comes off onto the machines themselves, and the rest is removed in the dyeing process). The man who works as a blender has a very dusty job, although the wool has been washed, and a mask is a necessary part of his equipment.

Rugdesigner – The manufacturing process

Saturday, April 25th, 2009

In order to make your design into a real size modern rug, we start by printing your design onto a transfer medium and then attach it onto the primary cloth. This will be the blue print from which we will hand tuft the yarns.
Printing the design onto the cloth minimize the tufting errors.
Rug Designer

We use 100% lamb wool, from our own yarns, which are manufactured and dyed in our factory. After the yarns have been tufted, the modern rug is hand cropped, to provide a levelled profile. A secondary backing cloth is applied which provides stability and durability of the product.

To provide our unique finish, we hand sculpture and trim the rug. Highlighting the individual design, creating textures and delicate profiles, increasing the definition and uniqueness of the modern rug itself.A final inspection assures the quality of our modern rugs.

At this stage any adjustments necessary will be carried out by our experienced rug masters. Once the modern rug passes the final inspection, we label our product as one in a limited collection.

The final stage is the packaging of our products. We endeavour to ensure that the product reaches you in the same condition as it leaves the factory.