| Prior
to 1984, no machineries were used in the production process. The
whole process from the sorting of the wool to the packaging stage
of the finished product was carried out by hand process. The production
process of Nepalese Tibetan carpet include:
Wool
sorting & Washing:
 Wool
from Tibet is generally imported in raw form requiring careful sorting
to pick-out the foreign particles such as vegetable materials. The
Tibetan wool also requires washing to remove dirts and executive
greases which is followed by sun drying for two to three days. The
Tibetan wool has a strong good fiber length is imported in scoured
form, good luster and a high resilient value. The New Zealand wool
are of 36 micron, 100 mm barb length and is identified as type 128.
British wool meeting regulatory standards have also started being
available in the market.
Carding:
The carding process allows the fiber stand
to flow smoothly when spinning. This is also the stage for blending
different wools and to ascertain the ratio of different origins.
Traditionally, carding was performed by hand and machine carding
was introduced when the industry grew. However hand carded product
is still available if a customer so desires.
Spinning:
The carded
wool is spun into yarn by hand using a charkha (Spinning wheel).
The thickness of the yarn depends on the quality of the carpet
and generally a 3 ply yarn is used .
Dyeing:
The traditional
pot dyeing method has been largely replaced by machine dyeing in
closed Chambers. Dues containing harmful substances such as AZO
are banned and dye-stuffs from renowned international manufacturers
are used. These dyes have a high degree of fastness. The dyed yarn
has to be dried in the sunlight for one to three days depending
on the weather. Pot dyeing and vegetable (natural) dyeing are still
being used by some manufacturers.
Carpet Knotting:
Carpet knotting
is an art by itself. The workers known as the weavers are well trained
and skilled in their art and has a very high versatility in knotting.
One or more weavers work on a loom depending on the size of the carpet.
Each weavers makes individual knots row after row. The designs are
chartered out on a graph and the weaver translate the graphic designs
into knots on a carpet. The dyed yarn is made into balls and scissors,
iron rod, levers, comb beaters are used as tools.
Trimming:
The finished
carpet taken off from the loom and the designs & patterns
are curved out by scissors.
The trimmed carpet
is washed with the fresh water & chemicals. The washed carpet
is dried in the sunlight up to four or five days. While the bulk
of the carpets are manually washed in Nepal a notable quantity is
washed in Switzerland.
Final
Finishing:
The dried
carpets are given the final finishing touch by retriming and stretching,
where necessary to bring it to as close to the ordered size.
Packing:
All washed
carpets are rolled and wrapped in polythene sheet and is sealed
at each end. Again, it is wrapped in Hessian cloth and sewn. Generally
around 14m2. are packed in each bale.
Payment:
Export
proceeds must be received through an irrevocable letter of credit
(L/C) or advance payment.
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