Story of our Rugs n ature o n y our f loor 4/73 Eastern Road, Browns Plains, Brisbane, QLD 4118,Australia Phone: 1300 13 2226, Fax: 07 305 47 282, www.aussbond.com.au
AUSSBOND JUTE RUGS HANDLOOM WEAVING PROCESS 11- WEAVING PROCESS 19- SUMMARY 18- PACKAGING 17. LATEX BACKING 16- SINGEING PROCESS 15- CUT ROLLS ARE SENT FOR TUCKING PROCESS 14- CHECKED ROLLS ARE CUT IN TO REQUIRED SIZES 13- WOVEN ROLLS ARE UNROLLED FOR QUALITY CHECKING 12- WOVEN ROLLS UNLOADED FROM THE LOOMS 10- SHUTTLE FEEDING 1- NATURAL FIBER SORTING PROCESS 9- COPS WINDING PROCESS 8- FEEDING PROCESS 7- LOOM FEEDING PROCESS 6- LOADING PROCESS ON THE HANDLOOMS 5- BEAMING PROCESS 4- YARN SPOOLING PROCESS 3- FIBER SORTING PROCESS 2- YARN SPINNING PROCESS Contents
AUSSBOND JUTE RUGS HANDLOOM WEAVING PROCESS spooling process, beaming process, weaving process etc village ladies and men using the old age conventional processes and these entire processes are also done by the further sent for clipping, nishing, singeing, passing hand-tucked and nished. These hand tucked pieces are pieces of required sizes and the ends of these pieces are in the form of rolls in the handlooms. These rolls are cut in to The Jute rugs in various design/weaves etc are woven are 100% labor oriented. process, treadle operation process etc all these processes which includes the cops winding process, shuttle feeding process, yarn spinning process, yarn sorting process, The natural ber handloom woven rugs are unique in various manual process like the natural ber sorting processes are highly labor intensive processes. It includes The conventional Wooden Handloom weaving more. handlooms that are inherited from the past 100 Years or house involved in the handloom sector has two to fteen sector in India is a wide cottage industry. Each and every in the handloom weaving sector. The handloom weaving Thousands of people in many villages of India are involved manufacturing peculiarities which is very much traditional. appearance and very much of fond worldwide due to its methods and processes.
NATURAL FIBER SORTING PROCESS The harvested jute bers or coir bers are coming in bunches / bundles. This natural ber received in bunches / bundles are further sorted according to the grade, colour and ber length. The natural ber sorting process is done by specialized workforces whom are traditionally called as “MOOPENS” or Technicians. The longest Jute ber available in natural colors / tones are sorted out and used for making the Jute yarn. This sorted jute ber is further sent for the yarn spinning process.
YARN SPINNING PROCESS The sorted ber is further sent for yarn spinning process. The yarn is spun by the village Ladies and Men using the conventional wooden, steel or iron wheels traditionally called as “RATT” which is an age old method. The yarns are spun in different qualities required in terms of twist, thickness, ply’s, runnage etc.
YARN SORTING PROCESS The handspun Jute yarn which is coming in bunches will be again sorted according to the colour, twist, thickness, ply’s, runnage etc. The sorting process is also done by the specialized workforces who are the experts traditionally called as “MOOPENS” or Technicians. The sorted and segregated yarns are further sent for spooling, cops winding and beaming process in line with the rug weave or design to be woven in the handlooms.
YARN SPOOLING PROCESS The sorted Jute yarn is further made in to hanks and these hanks are put on a triangle shaped conventional wooden winder, traditionally called as “PAMBARAM” and from these Pambaram’s the yarn is again winded to small wooden spools.
BEAMING PROCESS This conventional beaming process is the core process for arraying the warp yarns in a methodological manner. This is being done on a conventional bigger wooden wheel traditionally called as “WIMBLE”. The yarn spools are loaded on a conventional wooden stand and from these spools the yarns are winded to the wooden “WIMBLE” wheel. S ubsequently these yarns are transferred from this “WIMBLE” wheel to the wooden or iron beams traditionally called as “PAVUTADHI” .
LOADING PROCESS ON THE HANDLOOMS The beams or “PAVUTADHI” that are unloaded from the “WIMBLE” wheel are further loaded on to the conventional wooden handlooms. Two to ve beams are loaded on to the handlooms depending on the required weaves or designs. T hese beams are segregated as Warp beam, Slack Beam, Tight Beam etc while loading the looms, which are done in line with the required weave or design.
LOOM FEEDING PROCESS The yarns from these beams are segregated to warp yarn, slack yarn and tight yarns are fed on to the Reeds traditionally called as “ACCHU” in the wooden handloom. This yarn feeding process is also done according to certain arithmetical calculations and methodological arrangements in order to weave different designs or weaves.
COPS WINDING PROCESS The Jute yarns are winded to small cops traditionally called as “UNDA” for feeding the shuttles. The cops winding is also done using the very conventional method by the village Ladies and Men using wooden, steel or iron rims or wheels.
SHUTTLE FEEDING The cops or “UNDA” are fed on to the conventional wooden shuttles, traditionally called as “VALLAM”. These “VALLAM” or shuttle is used as weft yarn whilst the weaving process.
WEAVING PROCESS W eaving is the major process done in the conventional wooden handlooms, traditionally called as “THARI” and the weaving process is done by the highly skilled work force. Umpteen numbers of designs/weaves are being woven in handlooms. The rugs are woven in the roll form in the handlooms. Approximately 30 to 40 meters are woven in one warping or beaming depending on the weaves or the yarn texture used.
WOVEN ROLLS UNLOADED FROM THE LOOMS
WOVEN ROLLS ARE UNROLLED FOR QUALITY CHECKING
CHECKED ROLLS ARE CUT IN TO REQUIRED SIZES
CUT ROLLS ARE SENT FOR TUCKING PROCESS The cut edges of the rugs are further hand-tucked using iron needles and pullers which are traditionally called as “SUGI & ODACKU”. The warp and tight yarn in the cut edges are pulled in to the weft yarns using these needles and pullers “SUGI & ODACKU” .
TUCKED EDGED PIECES ARE SENT FOR FINISHING PROCESS The woven Tucked-end pieces are clipped, nished and passed in order to cross-check and ensure the quality.
TUCKED EDGED PIECES ARE SENT FOR FINISHING PROCESS The nished pieces are singed (blown with re) in order to burn out the excessive bers and to enhance the appearance of the rugs. This will also help to eliminate the insects and reduce moisture content in the rugs.
Latex Backing
PACKAGING F inally the goods are labelled/tagged and packed and as per the requirements of the customers.
SUMMARY The factory QC will inspect the goods that are singed and finished before packaging. The packaged goods are further offered for the midline and final inspections by the Quality Assurance Managers appointed by the customers or the agents of the customers. 4/73 Eastern Road, Browns Plains, Brisbane, QLD 4118,Australia Phone: 1300 13 2226, Fax: 07 305 47 282, www.aussbond.com.au
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