Our Rug Manufacturing Process in Nepal: From Brief to Delivery

Every order that leaves our Kathmandu facility follows the same six-stage production sequence. This page documents it. Trade buyers, interior designers, and hospitality buyers use it to understand what happens between brief submission and delivery.

Submit your design specification or request a trade consultation. We confirm feasibility and assign a production coordinator within 48 hours.

Our Process

From Raw Fibre to Finished Rug

Material Sourcing

We source natural fibres from verified suppliers across Nepal, New Zealand, China, and South Asia. Every batch is inspected on arrival before entering production.

Himalayan Wool - high-altitude Nepali sheep, dense fibre, long pile durability
New Zealand Wool - uniform staple length, consistent colour uptake
Chinese Silk - lustre pile inlay and detail work in high-density knotted rugs
Bamboo and Viscose - flatweave and hand-loomed constructions
Nettle and Hemp - natural plant fibres for eco-specification briefs

Material selection is confirmed with the client before dyeing begins.

Design and Production Specification

Our design team converts the client's reference into a production-ready specification. This includes:

Colour-matched yarn swatches (Pantone/RAL referenced)
Digital layout with construction notation
Knot density specification (40 to 350 KPSI)
Pile height and yarn weight per square metre
Final dimensions with tolerance allowances

No yarn is dyed until the client approves the specification in writing.

Dyeing

Our dye house operates using AZO-free, eco-certified dyes. Yarns are hand-dyed in batch lots matched to the approved colour specification. We dye in controlled conditions to ensure consistency across the full production run.

All dye processes meet GoodWeave environmental standards and are logged for compliance documentation.

Weaving and Knotting

Production is carried out by skilled artisans across our four construction methods:

Hand-Knotted - Tibetan or Persian technique. 40 to 350 KPSI.
Hand-Tufted - tufting gun on stretched backing, faster production
Hand-Loomed - flatweave on traditional frame looms
Hand-Woven - shuttle-woven, tight-structure flatweaves

Supervisors conduct in-progress checks at defined intervals during weaving.

Washing and Finishing

Completed rugs go through washing to set the pile, remove production residue, and achieve the final texture. Post-wash finishing includes:

Pile trimming to approved height
Stretching and blocking to final dimensions
Fringe finishing or surging (per specification)
Surface inspection for knot consistency and colour accuracy

Quality Control and Pre-Shipment Inspection

Every rug passes a structured quality check before packing:

Dimensional accuracy against specification
Knot density verification (spot-checked by count)
Colour accuracy against approved swatch
Surface and edge finish
Weight per square metre

Trade buyers receive a pre-shipment inspection report. GoodWeave and Label STEP documentation issued with every qualifying order.

Manufacturing

Production Capacity

Our facility produces 4,000 to 5,000 square metres of finished rug per month across all four construction methods. We handle orders from a single bespoke piece to multi-container bulk contracts.

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