PREPARATION (Dyeing)
Each custom-made carpet begins with the preparation of 100 % virgin wool from New Zealand. Using color references provided by the client, the wool yarns or other special yarn like silk are pilot-dyed to ensure a perfect match to the color specifications. After the correct color formula is achieved, large quantities of yarn are dyed using the best colorfast acid dyestuff available in the world market.

WINDING
The yarn is then wound into cones. By combining several colors together, a stippled effect is achieved. Twisting and conditioning create thin and thick yarn textures as required by the carpet design.

WEAVING (Tufting)
The process proceeds to the most intricate and demanding part of carpet making. Highly skilled weavers manually tuft the yarn into the heavy canvas - a job that requires a combination of skill, precision and patience. After the handtufting process is completed, quality control inspectors check and recheck the carpet seeing to it that all products meet the stringent standards for quality.

LATEXING & DRYING
The carpet is then stretched out for latexing. After mesh cloth is laid out on the carpet, compounded synthetic latex is applied by hand. The latexed carpet is placed under the infrared lamp dryer to vulcanize the rubber that binds the tufted yarn securely onto the cloth backing.

CARVING & SHEARING
The final touch is done in the Finishing section. Here, highly trained carvers with tools in their skilled hands work on every carpet design to bring out its elegant beauty. The carvers finish the carpet with hairline carving, beveling and embossing while the shearers apply tip shearing to give desired texture and thickness to each carpet.

QUALITY CONTROL
The carpet undergoes a final inspection. After passing exhaustive and rigid standards, the Quality Assurance label is affixed.

Our machine-made carpets are made with the same kind of care and precision.