In the Making

There are so many ways to make a rug or carpet; from hand made through to machine loomed, using wool, or mohair and alpaca, to jute and sisal or even recycled plastics. We work across all formats, and most rugs and carpets go through a broadly similar exercise in terms of preparation, creation and finishing. Using Tibetan or Persian hand knotted rugs as an illustration, as they are considered the finest examples, let us take you through the process.

Hand knotting is a centuries old skill, passed down through artisans for generations and matchless in terms of its method, longevity and results. We work closely with our craftspeople and mills to make sure that our work enhances and sustains the traditional craft and quality. The actual knotting techniques have vast variation depending on the qualities, regions and materials used.

Bespoke

Over 80% of our work is bespoke and we are proud to provide a tailormade service for projects that require something completely unique. With an exceptional knowledge of design possibilities and weaving techniques, and a deep
understanding of a project’s potential challenges, the Peter Page team’s specialist experience across the full spectrum of carpets and rugs streamlines the process with standout results. From providing early project advice on design, options and weaves through to a fully managed installation – bespoke commissions are an entirely custom process; made for your space.

Step By Step

SORTING & CARDING

The story begins when the raw fibres are selected and rigorously sorted by hand, removing imperfections, burrs and any vegetation. This careful selection is washed then carded. Carding gently teases the fibre from its natural state into straighter more uniform lengths. This yarn is then spun, expertly binding it into threads that can be baled, ready for dying and weaving. This operation is meticulous and precise with different yarn weights being created for specific knot counts, all measured by touch and feel.

DYEING

The bales are then portioned for dyeing, based on the colours specified and the rug size, as illustrated on the weaving map. The dyeing process is almost alchemical; overseen by the experienced dyemaster, the hues are scrupulously created using precise colour measures to ensure the perfect saturation based on amount and material. It is time consuming and precise, with many factors to consider – yarn darkens as it dries, finer wools take on a natural sheen, high lanolin content can prevent the fibre taking on as much dye. The dyed yarns are then taken up to the rooftops to dry naturally in the sunshine, laid out across a giant web of drying lines, before being balled ready for the loom.

WARPING

The loom is warped up taking account for the size and knot count, with the warp threads strung closer together the higher the knots per square inch. Behind the loom lies the weaving map, a plotted grid of the lifesize pattern of the rug, often water coloured to give the weavers a true illustration of the design they are creating.

WEAVING

The weaving itself is a well practiced dance; each weaver knows his or her part of the pattern and to create a uniformly woven rug, all the weavers must work in synchronized rhythm. In the Persian knot the yarn is knotted directly around the vertical warp, or in the Tibetan knot it is looped around the vertical warp and a metal rod. Hand knotting requires patience, diligence and experience; a single weaver weaves about two to five inches a day.

(For hand loomed rugs, this is where the only deviation in the process occurs – the
hand tied knots are replaced by a loop knot and a shuttle, which beats down the line of knots, once the line is hammered tightly to its neighbour the loops are cut, creating a cut pile.)

WASHING

The completed rugs are then cut off the looms and taken for washing. They are
thoroughly scrubbed back and front with giant paddles that push fresh water through the pile, removing any loose fibres, excess dye and any impurities. Then they are taken back up onto the roofs, where they are stretched like giant canvases to dry in the sun one final time. How long they take to dry depends on their makeup – cut pile wool rugs are very dense, whereas flat weaves are much lighter – and on the weather – monsoon season and storms can cause significant delays.

FINISHING

Once the rugs are dry they are taken to be sheared, and the pile is cut neatly to a uniform height by hand. The shearing process also involves the precision clipping between variations in colours and patterns to bring a clean delineation to the rug’s final appearance.

Finishing and binding are the final steps in completing the rug; the responsibility of a highly skilled finisher, the edges of the rug are expertly wrapped in a tight yarn to match the rug’s design and the binding tape is sewn on to complete the making journey.