Rug Production Methods
Ever looked at your rugs specifications and wondered what it all actually meant?
Below we try to explain the different rug production methods so you as a customer know and understand exactly what it all means.
Rugs can be classified into two sections. Flat-weave and deep pile. Flat weave rugs are made using warp and weft and are thinner than deep pile rugs. Deep pile rugs are the more popular type and most modern contemporary rugs are made using this method.
Most rugs in Europe and the USA are made by machine. The most popular method of production is on a machine called the Wilton Loom. Controlled by computers the manufacturers can provide infinite designs at amazing speed.
Woven Wilton rugs are usually made of wool or polypropylene. When producing Woven Wilton wool rugs most manufacturers tend to use New Zealand wool. Although it is more expensive it provides considerably easier dying properties and a far superior finish. However this will add to the cost of the rug. Polypropylene Wilton rugs come in two types which are called Heatset, that is processed to produce a soft wool-like feel, and Bulk Continuous Filament. These rugs are a great favourite of manufactures because they are easy and inexpensive to produce.
Handmade rugs are usually produced in India, China and the Middle East where labour is more affordable. They come in a range of designs and styles which we have listed below.
Hand Knotted Rugs
Hand knotting is an ancient production method that was developed in Persia in the Bronze age. This involved each tuft being knotted by hand to the backing. Today the same basic proccess still applies. There are two different methods of knotting they are a Persian knot and a Turkish knot. The Persian knot is less likely to leave gaps as they are finer tufts. Handknotted rugs are the most expensive rug to manufacture as the proccess takes some time. Most handknotted rugs are produced from wool or silk. The fibres are hand-dyed and most styles are influenced by the region in which they are produced.
Mainly produced in India and China from wool and viscose. Hand tufting is the fastest way of producing a rug by hand. Commonly used for the manufacture of shaggy rugs or modern contemporary rugs. The rug is manufactured by shooting the yarn through the backing of the rug with a hand held gun. Once the design is finished a second backing is applied with adhesive and then the rug is hand carved to produce the texture, depth and dimension.
Hand Loomed Rugs
Usually produced from wool in the far east these rugs are created on a loom which is powered by an operator using their hands and feet.