The design of the rug is printed on a sheet of paper or plastic. Its outline is perforated with a needle. A canvas is stretched in a frame. The pattern is then placed on the canvas and coated with ink. The ink passes through the holes and prints the design.
With the help of a manual or electric gun, the wool is introduced by tufts into the canvas. The manual gun is more precise and used to reproduce a fine design accurately. It is common to use both tools on the same rug.
Colours are applied on after the other. When all the patterns are done, the rug is turned over and shaved.
The tightness of the backing determines the quality of the rug.
The regular tightening is 10 picks (density 3 kg/m²).
For a rug intended for heavy traffic, it is preferable to use 12 or 14 picks (density higher than 3 kg/m²): the pile strands will be tighter and will wear out less quickly than if they were less compact (since the pile is layered).
Another method is to use a strand with a larger number of threads to obtain a more compact pile.
The height of the pile is set by shaving during finishing.
The backing is then coated with latex glue and a finishing cloth is applied. This is done to fix the strands since they are not knotted.
Pure latex or a high-end compound is recommended to ensure that the rug can be folded easily.
The backing fabric glued to the backing of the rug is usually unbleached. It may be black. Some manufacturers dye the backing in the dominant colour of the design.
Note: Be careful with latex. Poor quality latex (mixed with sand, for example) gives off an odour, becomes brittle and crumbly over time.
Why choose a tufted rug?