Galiche Art Rugs are woven with supervision and strict quality control, most rugs are still woven with contract weavers or home weavers just like centuries old tradition, we select vendors with a high standard and then develop them as partners, together we create them as individual pieces of art.
Design is the first step in creating a rug, Most designs are Persian and ornamental though now there are a lot of transitional and modern designs coming up. Designs are selected on basis of their merit with customer inputs that what they can sell and what is in demand. The design is then transferred to a graph representing the quality (knots) the rug will look good at. Next come coloration, majority of rugs are still made in traditional colors of Blacks, Reds and Ivorys but a growing demand is there for fashion forward colors, our customers recommend colors from time to time based on the demands in stores, we also stay on top of color forecasting’s and women fashions for our color inspirations.
Once the map is done and quality is set, the wool is selected, based on design of the rug, we use either or all like New Zealand Wool, Indian Wool, Persian Wool, Mountain Ghazni or Blend of any of these wools, We also use Natural Silk, Art Silk, Rayon, Bamboo or Cotton, Sometimes we make rugs of natural fibers like jute and hemp, the wool can be handspun or machine spun, hand carded or otherwise. Once we receive the wool we are all set to take next steps.
The spun yarn is dyed, Most rugs are made in chrome dyes, the dyed wool is tested for color fastness, also we use conventional dyers or regular home dyeing (like old days) depending upon how much wool is needed to be dyed. Dyed yarn is sundried.
Looming of the rug, Using the highest standard of cotton or jute in warp and weft, the painstaking process of weaving start, How many weavers are weaving a rug is strictly dependent on the size or rug, Using the highest standard of cotton or jute in warp and weft, the painstaking process of weaving start, How many weavers are weaving a rug is strictly dependent on the size or rug, While a 4x6 will be woven by one, a 9x12 or 10x14 will take 3 to 4 weavers,A Custom 18 ft wide rug being made recently has 5 weavers side by side, The weaving process is an art, one has to see it to believe it, Its hard work and great skill. It takes approx. 30-90 days to weave the rug depending on the size, larger the rug, more the time. We have inspectors looking at quality all the times and monitoring the yarn and correctness of designs, Once the rug is woven to full length it is ready for next steps.
When received a raw rug has a lot of wool, here starts the process of finishing, Rug is given a shearing, the clipping of pile height is done by machine after combing the rug to take out excess and dead fiber out of yarn. The the rug is sent for washing, Each quality has it standard washing procedures, the washing makes the yarn soft and colors rich. Then again the rug is sheared to attain optimal pile height so that designs and motifs are clearly seen. Some rugs are washed up to 3 times. Chemicals and Herbs are used to get the right finish.
Washed rug is crooked, The rug is then stretched using iron rods and pulled to bring it to a straight size, The process thukai straightens the border and makes it even all over the rug. Once the rug is stretched it is sent for final finishing.
Binding, Fringe Knotting and carefully inspecting the rug for softness,this helps in standardizing the methods to deliver a carefully crafted art for the floor and knots are the final touches given to the rug.
Final Finished rug is vacuumed thoroughly and then carefully packed mostly double to avoid any freight damage.
