Carpet masterpieces from Nepal are obviously the work of virtuosos! Gifted and experienced hands make carpet dreams come true with an ancient technique. From sheep to hand knotted carpet from Nepal: The making of a hand knotted carpet starts with the sheep shearing. The wonderful pure new wool is washed und dried before it is used for further processing. Afterwards the wool is carded by hand, by pulling the wool with experienced grip and carding it in one direction. This allows one continuing thread for the subsequent spinning. The naturally white spun yarn is now ready to be dyed in wonderful colours. This so-called piece dyeing is done by using traditional formulations to get the requested colour shades. With the help of a spectrophotometer every single colour is calibrated and realized with colour fidelity. Before the knotting can start some other preparations have to be made. The design specifications are drawn proportionally to the size. The cotton threads are tensed evenly and precisely on the knotting chair. This is very important in order to get a carpet of precise measurements and shape. Now the first knot for the carpet can be tied! Tibetan craftsmanship knots with the traditional loop knot. These loops are put around a rod and afterwards sliced row by row. Thus the pile is spread and the carpet gets its marvelous fleecy character. When the carpet is finished, the pattern is emphasized by precise relief shearing. Colour and pattern elements are outlined by hand with scissors. Then the whole carpet surface is evenly sheared. The following refinement, the hand washing, is one of the most important steps in the process, responsible for the lively look of the carpet. The refinement washing gives the Nepal carpet its exclusive shine and the naturally shading surface structure. At the same time the carpet is cleaned from loose wool pieces and becomes soil-resisting. The carpet is spanned for drying, so it keeps its shape. The last quality control includes a
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INTRODUCTION OF NEPALESE HANDKNOTTED CARPET
Carpet masterpieces from Nepal are obviously the work of virtuosos! Gifted and experienced hands make carpet dreams come true – with an ancient technique. From sheep to hand knotted carpet from Nepal: The making of a hand knotted carpet starts with the sheep shearing. The wonderful pure new wool is washed and dried before it is used for further processing. Afterwards the wool is carded by hand, by pulling the wool with experienced grip and carding it in one direction. This allows one continuing thread for the subsequent spinning. The naturally white spun yarn is now ready to be dyed in wonderful colours. This so-called piece dyeing is done by using traditional formulations to get the requested colour shades. With the help of a spectrophotometer every single colour is calibrated and realized with colour fidelity. Before the knotting can start some other preparations have to be made. The design specifications are drawn proportionally to the size. The cotton threads are tensed evenly and precisely on the knotting chair. This is very important in order to get a carpet of precise measurements. And shape. Now the first knot for the carpet can be tied!
Tibetan craftsmanship knots with the traditional loop knot. These loops are put around a rod and afterwards sliced row by row. Thus the pile is spread and the carpet gets its marvelous fleecy character. When the carpet is finished, the pattern is emphasized by precise relief shearing. Colour and pattern elements are outlined by hand with scissors. Then the whole carpet surface is evenly sheared. The following refinement, the hand washing, is one of the most important steps in the process, responsible for the lively look of the carpet. The refinement washing gives the Nepal carpet its exclusive shine and the naturally shading surface structure. At the same time the carpet is cleaned from loose wool pieces
and becomes soil-resisting. The carpet is spanned for drying, so it keeps its shape.
The last quality control includes a precise measuring and documentation of every single carpet. It takes time to do a thing well… Our handknotted Nepal carpets are purely handmade from the beginning to the end. It takes 12 to 16 weeks for such a carpet dream to come true.
The Materials We Offers
Tibetan Wool: Also known as Himalaya wool is a wool produced from a “Changphel” a high land sheep, The sheep graze over 14,000 feet by the nomads people where temperature can be extremely cold, due to the extreme condition sheep develops long fleece, tensile strength, and have a high level of Lanolin content which makes Tibetan wool the most durable, soft and luxurious wool in the world. Tibetan wool has many different natural colors from Dark to off white. We mostly use Tibetan wool to produce our rugs.
New Zealand Wool: is a wool from merino sheep comes from Australia and New Zealand, it is one of the excellent quality finely crimped and soft wool comes in pure white color. New Zealand wool is best for the light color to pure white color rugs. It is durable, soft and very good color fast. New Zealand wool can also be blended with Tibetan wool, silk and other materials. which gives different characteristic when blended with different materials.
Chinese Silk: we use is the highest quality ready made spun silk comes from china, we use 140NM/2 quality Chinese silk which is very soft, luxurious and expensive silk. Chinese silk we use is a silk from silkworm (Bombyx mori) cocoon. It is very well known high end silk. The rugs made with this silk is highly soft, shinny and luxurious. We make 100% Chinese silk rugs or wool and silk combination as requirements.
Local Silk: is a silk produced in Nepal, we directly buy silk cocoons from the farmers and process it in our factory, This silk is of good quality and the rugs we make from local silk are of very reasonable price. The rugs from local silk are soft, shinny and very durable. The local silk are the best option silk with good quality and best price.
Viscose: Also known as art silk is a solution of cellulose xanthate to make a fiber viscose rayon, it is made from regenerated wood cellulose, Viscose is not a silk but when weaved into rug, it looks and feels similar to the silk but shines more artificially. Viscose is a cheapest price material widely used to substitute the silk in very low price.
Hemp: is a natural fiber from a cannabis plant which grows in the hills of Nepal, Hemp is the strongest fiber and 90% water resistant. Hemp rugs are very durable, rough texture is a unique characteristic of a hemp rug. It is great for the extremely high traffic area. Hemp rugs are widely used in natural colors which have a abstract colors effect naturally.
Linen: is a natural fiber from a flax plant and one of the most popular natural fiber in the world. Linen rugs are cool to touch, lint free and very durable. Linen rug is recommended on the hot weather areas Linen have a high natural luster; their natural color ranges between shades of ivory, ecru, tan, or grey. linen can be dyed in any color from bleached white to black.
Nettle: Also known as Allo is a natural fiber from a nettle plant. It grows wildly on the high mountains of Nepal, Nettle is an all rounder plant which is never wasted from leaves to the root. Root of nettle is used as a diabetic medicines, steams are used for fibers and leaves are used as a tea or vegetable curry. Stinging hairs of nettle plant contain formic acid, serotonin and histamine which makes the nettle plant natural anti pest property hence the nettle rugs are widely used without dyeing and does not require any rug treatments.
Banana silk: is a natural fiber from banana fruit tree. Our banana fiber comes from the Planes of Nepal which is cultivated mainly for the fibers since 1999. Our banana fiber is hand made fibers and has a great durability comparing to the machine made banana fibers. Banana fiber shines like silk but has a unique casual characteristic after weaved into rugs. The natural color is white and can be dyed in any colors as required.
We also have Bamboo fiber, cactus fiber, corn fiber available. please contact us for further inquiry.
Colors and dyeing
Our materials are dyed with swiss chrome AZO harmful chemical free dyes or vegetable dyes depends on your requirements or a hue of the colors. Our dyeing process starts from 2 major steps which we believe is the most important on dyeing process. (I) Warm water washing of the materials before dyeing and (II) Dyeing a small sample tuft before to confirm the accuracy of the required colors.
Vegetable dyes we use are 100% natural dyes from plant and mineral source like Walnut, Rheum Australe, Indigo, Madder root, pomegranate peel, Henna leaves, weld, Hollyhock flower, Gallnuts etc, these vegetables are combined together to get different colors. The best thing about vegetable dyeing is a natural abstract color characteristic and 100% eco friendly. vegetable dye is bad on color accuracy so the colors may not match exactly like requirements.
Communicating colors with our clients is a vital process of rugs production. We use ARS color system to communicate the colors. We have ARS 1200 wool color box, ARS 600 wool color box, ARS viscose 700 box, Pantone home and fashion color card, Pantone Formula guide coated, un-coated and matte. We can also match colors from your sent colors samples in any form like fabric swatch, papers, tufts etc..
We can also create custom color pom kits, please click here to learn more about custom color pom box.
Weave and Knotting types
Our rugs are made entirely by hand from yarn making, dyeing, weaving to finishing. Our rugs are made by ancient Tibetan rug weaving technique. Our rugs are woven on iron and wooden frame in vertical looms which is warped with cotton yarn from top to bottom. A metal rod is pushed horizontally across the warp and yarn is loop knotted over the rod, then onto the warp to make a pile. When the whole knot is made, a crossed cotton weft is put across to separate the pile, then combined and compacted with a wooden hammer. It is then slit with sharp blades across the metal rod to make a cut pile or pulled out a rod without cutting to make loop pile. This process is repeated until the rug is made.
Our knots density is measured by knots per square inch (KPSI) basis. We produce 45 knots, 60 knots, 80 knots, 100 knots, 120 knots, 150 knots and 200 knots per square inch rugs depends on the design and your requirements. Our standard and most popular quality is 100 knots which is good for simple to medium complex designs. 100 Knots means it has around 100 knots per square inch but sometimes knots density may be plus or minus to match the required designs accurately.
Knot count in our rug does not effect the quality of our rugs in terms of durability because whether it is higher knot counts or lower it is weaved in a same way of knotting technique. Knot count only effects the perfection of the designs, the higher knot means finer design. Knot is exactly like a computer or television screens as lots of pixels means high definition or clearer image.
Following are the picture of different knot samples, here you can see the difference of knots from 80 knots to 200 knots in a same design:
Pile & Thickness
Pile refers to the yarn that rises above. We can produce rugs in 2 different pile style. Cut pile, Loop pile or both pile combination, like a picture you can see at the right side. When the rug is woven, the yarn is knotted around a metal rod. This yarn is then cut on the top to expose the inner strands of the yarn. Typically all yarn in the rugs is cut pile but occasionally this can also be left uncut or looped giving a different outlook of the rug. We can make cut pile and loop pile in a single rug. You can specify us on your design, for cut pile or a loop pile.
Pile height refers to the height or thickness of the rug. Typically our rugs are 4 mm high for 80 + Knots and 5 mm high for below 60 knots rug at a normal standard, but can be woven at your required pile height. Different pile heights can be used in the same rug to create a more multi-dimensional effect. Higher pile heights create softer rugs and can have a luxurious appeal.
Pile height effects the weight and cost of a rug, higher pile height costs slightly high due to materials used to produce a rug. We can produce 4 mm to 10 mm or more as your requirement.
Our production process does not use any type of electronic machineries. The whole process from the sheering of the sheep to the packing of the finished rugs is carried out entirely by hand. Manufacturing of the different material rugs uses different process at the first two steps so this page only contains the information of our woolen rug making process :
Wool sorting & Washing
We Import Tibetan wool from the Tibet which comes in a raw form right after sheering the sheep. We short the raw wool by hand to pick out the foreign materials such as vegetables and wood particles, and separate the different natural color of the wool. After shorting wool will be washed in warm water to clean out the foreign particles. Our Tibetan wool is 100% pure Tibetan wool from high Himalaya and are not mixed with any other wool to maintain the quality.
Carding is the process of combing the wool so that no fibers are intermingled together and to maximize the purity of wool by removing all the foreign particles if any. Carding helps on spinning of the yarn from the wool. carding is done by the special traditional steel and wooden hand made comb.
Spinning is the process of making a yarn. After carding spinning is carried out with a traditional wooden spinning wheel called 'charkha' in Nepalese. in the process of spinning the wool fibers are drawn and twisted to make the yarns in desired thickness, the thickness of the yarn is made according to the knots of a rug, for lower knots like 45-60 knots the yarn will be thicker comparing to the 100 knots yarn.
After the yarns are made by spinning process, the yarns are ready for dyeing. Before dyeing the hank of yarn will be washed with warm water again to ensure the best quality of dyeing. The dyeing is done in a big pot with a wheel burning wooden or gas stove underneath . We use swiss chrome azo-free dye or vegetable dye as per clients demand.
Rug weaving is performed by hand reading graphs of a design which is hanged in front of the weavers on a loom, The graph will be 1:1 scale. Our Carpet weaving is done with the traditional tools like scissors, iron-rod, levers, comb beater, iron hammer etc. This process involves skills and craftsmanship.
Clipping and carving
After rug is weaved and comes out of a loom a surface pile of a rug is then clipped by the traditional big size scissor called 'khapsi', this will smoothen the level of pile evenly and gives a shiny and even surface texture. The design edges will be carved by scissor for the luxurious look.
Washing and drying
After clipping and carving, rug will be washed with the help of long wooden flappers which helps to rub the surface of a pile and to carry out the water properly for faster drying. The natural soap like sapindus and the normal liquid soap is used to wash the rugs. After washing rug will be dried on direct sunlight for about 4-7 days.
Second / final Clipping and carving
After rugs are dried it is again clipped one more time to ensure the even surface and also carved the edges of the design one last time to ensure the perfect and clean design finishing.
After final clipping and carving rugs are stretched from all four sides using metal frames and hooks, keeping on a frame for at lest 24 hours. It helps in maintaining the perfect shape of the rug.
Final finishing and checking
After taking rugs out of a stretching frame it is then checked by our professionals. It is mainly checked for the size, shape, surface, designs, stains, etc... This is the most important part and we treat it as a very serious step.
Packing and shipping
After rug is approved by the management it is then packed. We never fold a rug for packing because there could be a fold marks on a rug, we roll the rugs and put it in a transparent heavy duty plastic bag as a first protection, and then we warp a rug with a heavy duty tear and water proof sheets from above. For heavy weight rugs we also warp with a burlaps for extra protection on the transits.
Custom rugs Order
We Produce custom design hand knotted rugs totally following your instructions. Our highest priority for custom rug is to match your requirement with great accuracy. We are capable of producing your rug in any design, size, shape, colors, pile thickness at 45 knots, 60 knots, 80 knots, 100 knots, 120 knots, 150 knots and 200 knots per square inch density. We have a wide range of materials like Tibetan wool, New Zealand wool, Chinese silk, Hemp, Banana fiber, Bamboo fiber and much more materials to choose from. We can combine two or more materials in a single rug if required.
Our custom rug service is great for the rug and carpet designers, importers, interior designers, and the rug stores around the world.
Please Contact us for any further inquiry .
We accept your design via email or by courier, the files format can be .JPG, .PDF, .PNG files. A art work can be a vector or raster files, photo graph or a sketch.
We use color poms and tufts kit like ARS color box, Pantone color cards and Nilam color threads to communicate the colors. You can also courier us your own colors to match. Your color sample can be fabric swatch, paper chips, threads or almost any thing from which we can see and match your colors.
You can order a strike off samples with us to see how a final result will be. We can produce a sample strike off from 30X30 cm to any size as you need. We can do different versions of samples as you like to see and choose from different materials, thickness and quality.
After your order we keep you sending the pictures of a rug being weaved in our loom and keep you updated. In this process we will send you many pictures of rug from different angle so that you can see how it is going.
It is crucial to finish your rugs in time. For this reason we have trained our weavers and inspection team to work in a right way. We will always ship the rugs before our quoted time which we provide you at a time of your order.
Shipping of a rug can be made with courier or cargo according to your decision. By courier it takes 4-7 days for rugs to arrive at your door. We also offer cheapest price local agent air cargo which takes 6-8 days shipping time. We will provide you different shipping options in a time of price quotation. Contact us now to discuss about your project.
Color poms and Tuffs
We provide color poms and tufts service within a week.
When you are not sure how your colors looks in wool, silk or any other materials, we can dye a small sample and ship it to you, normally it take 7 days for you to receive.
We can also produce big quantity of color poms in your required colors, this helps you to make your own color kit, cost of making color kit depends on number of colors. When we produce your color kit, we actually make 2 kits at a same time. We ship one set to you and we keep next one for our record. This helps us to communicate the colors.
Besides color poms and tufts we can also weave a small rug swatch in 5X5 cm or any custom size. This help you and your client more accuracy on selecting the colors.
If you are interested on making your own colors kit you can send us your colors by courier. You can send us color fabric swatch, color paper chips, color threads, wool, silk, leather swatch or almost anything from which we can see colors to match. You can also provide us Pantone color codes. You can give your own codes or name for the colors which we will tag on each color samples.
Readymade color kit
We also have ready made color kit box, we have ARS 1200 wool box which has 1200 colors, ARS 600 wool box which has 600 colors and ARS 700 viscose box which has 700 colors. Please contact us for price and order.
Strike off and Samples
We provide strike off and samples service in great turn around time.
Strike-offs are available to ensure the color and texture of your rug that accurately represents the feel of your finished product, yarn characteristics, color combinations, etc. Strike off means a sample from a selected area of your large size rug. We can produce strike off in 30X30 cm, 60X60 cm or as required. We have a great discount for our regular clients or free depends on the value of the strike off samples.
We can also produce samples of different knots, pile height, materials and colors, which helps you to increase the sales.
We also have time saver sample pack ready available, which includes, 100 knots, 30X30 cm samples in different colors. We have the following samples in stock from which you can choose from:
Time saver samples pack:
1. 100% Tibetan wool, 100 Knots, 4mm
2. 100% Tibetan wool, 100 Knots, 10mm
3. 100% Chinese silk, 100 Knots, 4mm
4. 100% Chinese silk, 100 Knots, 10mm
5. 100% Local silk, 100 Knots, 4mm
6. 100% Local silk, 100 Knots, 10mm
7. 100% Art silk (viscose), 100 Knots, 4mm
8. 100% Art silk (viscose), 100 Knots, 10mm
9. 100% Hemp, 100 knots, 4mm
10. 100% banana fiber, 100 Knots, 4mm
11. 100% Bamboo fiber, 100 Knots, 4mm
12. 100% Allo, 100 knots, 4mm
If you have any of the samples or strike off request please contact us.
Nepart Gems & Jewel Collection
Golguphaka - 29, Kathmandu, Nepal
Mobile : +977-9851048821
Phone : +977-14385792, +977-14390484
Fax : +977-14385792