o n y our f loor 4/73 Eastern Road, Browns Plains, Brisbane, QLD - - PDF document

Story of our Rugs

nature

• n

your floor

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 1- NATURAL FIBER SORTING PROCESS 2- YARN SPINNING PROCESS 3- FIBER SORTING PROCESS 4- YARN SPOOLING PROCESS 5- BEAMING PROCESS 6- LOADING PROCESS ON THE HANDLOOMS 7- LOOM FEEDING PROCESS 8- FEEDING PROCESS 9- COPS WINDING PROCESS 10- SHUTTLE FEEDING 11- WEAVING PROCESS 12- WOVEN ROLLS UNLOADED FROM THE LOOMS 13- WOVEN ROLLS ARE UNROLLED FOR QUALITY CHECKING 14- CHECKED ROLLS ARE CUT IN TO REQUIRED SIZES 15- CUT ROLLS ARE SENT FOR TUCKING PROCESS 16- SINGEING PROCESS

• 17. LATEX BACKING

18- PACKAGING 19- SUMMARY

Contents

AUSSBOND JUTE RUGS HANDLOOM WEAVING PROCESS

The natural ber handloom woven rugs are unique in

appearance and very much of fond worldwide due to its manufacturing peculiarities which is very much traditional. Thousands of people in many villages of India are involved in the handloom weaving sector. The handloom weaving sector in India is a wide cottage industry. Each and every house involved in the handloom sector has two to fteen handlooms that are inherited from the past 100 Years or more.

The conventional Wooden Handloom weaving

processes are highly labor intensive processes. It includes various manual process like the natural ber sorting process, yarn spinning process, yarn sorting process, spooling process, beaming process, weaving process etc which includes the cops winding process, shuttle feeding process, treadle operation process etc all these processes are 100% labor oriented.

The Jute rugs in various design/weaves etc are woven

in the form of rolls in the handlooms. These rolls are cut in to pieces of required sizes and the ends of these pieces are hand-tucked and nished. These hand tucked pieces are further sent for clipping, nishing, singeing, passing processes and these entire processes are also done by the village ladies and men using the old age conventional 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

• f 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.

Subsequently 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.

These 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

• r 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

Weaving 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

• r 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

• rder 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

Finally 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

• ffered 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