Manufacturing Methods
Rugs are produced using different techniques, which leads to significant differences in quality, appearance and price. They can be produced both by hand and by machine. Traditional manufacturing methods include weaving and knotting.
Woven rugs
Woven rugs are characterised by a smooth, flat structure without a pile. The warp threads are usually made from cotton or linen and are completely covered by the weft thread made from wool. The threads lie closely together, forming a durable surface. While only traditional looms were used in the past, production today is often carried out using modern industrial machines.
Shop woven rugsTufting process
The tufting process is widely used today. The yarn is worked into a backing material using a tufting machine or gun – similar in principle to a sewing machine. Hand tufting typically uses a single needle, while machine processes use multiple needles simultaneously. This method is comparatively fast, which means tufted rugs can often be offered at a lower price point.
Knotting technique
Rugs with a dense, soft pile are created using the knotting technique. Individual knots are tied around the warp threads, and each row of knots is secured with weft threads. Once complete, the pile is evenly sheared. The quality and value of a rug increase with the number of knots per square metre. Particularly high-quality rugs can feature several hundred thousand to over one million knots per square metre.
Shop hand-knotted rugsHand-knotted
Hand-knotted rugs are traditionally made by skilled craftspeople. The warp threads are stretched on a loom, into which pile knots are individually tied. Each row of knots is carefully secured. The fineness of the yarn and the knot density largely determine the quality. Over generations, different knotting techniques, patterns, colours and regional styles have developed.
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Hand-woven
Hand-woven rugs are made on traditional looms and generally have no pile, which means they can be used on either side. Once the warp threads are stretched, the weft thread is woven through horizontally. Depending on the material thickness and weave density, the structure can range from fine to rustic. Hand-woven rugs are usually lighter than high-pile rugs and can be either plain or intricately patterned.
Shop hand-woven rugsPatchwork
Patchwork or vintage rugs are made from fragments of old, sometimes antique rugs. The individual pieces are carefully selected, cut and sewn together. Additional reinforcement on the reverse ensures stability and longevity. Before processing, all pieces are thoroughly cleaned. Many vintage rugs are colour-neutralised or re-dyed, giving them a modern appearance. Each patchwork rug is unique.
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Hand-tufted
Hand tufting is a semi-manual process for producing high-quality pile rugs. Using a tufting gun, yarn is worked into a stretched base fabric. The back is then glued and the pile is sheared evenly or in a relief-like pattern. Hand-tufted rugs are durable, high in quality and offer great creative flexibility at an attractive price-to-performance ratio.
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