The process begins in the Himalayan mountains of Nepal, where sheep are reared and herded for their lanolin-rich wool. To suit different projects, we also choose from a range of other natural fibres: Tibetan wool; New Zealand wool; Chinese silk; banana silk; linen; cashmere.
Washed and Spun
After shearing, the raw wool is hand-washed in the Himalayan glacial rivers and left to naturally dry on the banks. Transported to our factory, the raw wool is carded then spun into yarn, ready for the colour-dyeing process.
Dyeing and Drying
In the Dye House, bespoke colours are mixed and sampled, to ensure an accurate match to the rug design, from vibrant blues and greens, to subdued neutrals. The yarn is then soaked in large pots of heated non-toxic dye. After removing, the newly coloured yarn is left to dry and then spun into balls.
Knotting, Weaving and Tufting
With the newly spun balls of yarn, weaving and knotting is completed at the hands of our Nepalese artisans, on traditional wooden looms. A hand-drawn rendering of the rug design sits behind the loom for guidance on knot placement. All of our rugs are made with a minimum of 100 knots per square inch, allowing for the most precision and finest detail in design. For budget and time sensitive projects, your rug can be hand tufted - requiring less precision, without compromising on quality or design.
The Final Stages
Once woven, the rug is cut away from the loom and then thoroughly hand-washed. The rug is trimmed by hand, leaving a perfectly even pile to the touch. Where the design calls for it, finishing techniques such as pattern clipping are completed. The rug is ready to ship and be installed into its new interior.