Have you always wanted to know how our rugs are made? Well, that's a good thing! Here we explain step-by-step how the production process of our rugs is set up and how we get to the beautiful finished product.
This beautiful natural product is the basis of our rugs. Wool has many advantages: it has a long lifespan, is dimensionally stable, self-cleaning, durable and gives a beautiful, natural look to the rug. The wool we use originates from New Zealand. The sheep here are known for their extremely fine wool structure. In addition, this wool has a white colour. This makes the paint adhere better and we can deliver our carpets in a multitude of colours! After the sheep have been sheared, the wool is sent to Morocco in large packages. In a town near Rabat the whole production process takes place.
Once arrived in Morocco, the wool is unpacked and pulled apart to form wool flakes. These wool flocks are then dyed in various colours in large dye baths. As few chemicals as possible are used for the dyeing. Experience has shown that blended carpets fit in better with various interiors than the plain coloured carpets. For this reason, our colour numbers always consist of a mixture of various colours. First, the dyed wool flakes are selected by hand according to fixed colour recipes and mixed in a machine. The mixed wool flakes then end up on a belt where the yarn is made.
After the yarns have been made, they are washed three times at 90 degrees. This way the wool shrinks around its jute core. This gives more grip to the wool and makes sure that the carpets are less fluffy, because of course nobody wants that! After washing, the yarns are hung up to dry well.
When the yarn is dry, the rug can be woven. This is also the technique that is used in Morocco. It is a centuries-old tradition to manufacture rugs in this way. According to the local culture, the rugs are woven exclusively by women, by hand. The thickness of the yarn (we use three), the way it is
The thickness of the yarn (we use three), the way it is fed into the loom (the technique) and the distance of the warp threads determine the appearance of the rug. Depending on the type and size of the rug, it is woven by one or two people. The more complex the technique and the larger the rug, the longer it takes to weave the rug.
When the rug is woven it is cut from the loom. The ends of the warp threads are knotted together and to work them out of sight, finishing edges are added to the end edges.
The ends of the warp threads are tied together and to work them out of sight, finishing edges are put on the head ends. This can be a woven, woollen border, a cotton trim or woollen fringes. The type of border differs per quality. After finishing, the rugs are rolled out and any unevenness is removed or repaired.
When the rug passes the inspection, it is packed in two layers of biodegradable plastic. It is then transported by truck to the Netherlands. Once they arrive in our warehouse, the packages are checked and the rugs are sent to you our dealers so they can deliver them to you. Because of the multifaceted nature of the production process, it is hopefully clear why making a customised rug in any colour and the associated transport takes approximately 6 weeks.