Manufacturing Process

1st Phase

Raw silk unwound from its cocoon is first washed in hot water of 70º-80ºC with soap. The soap is melted inside hot water in boilers, then raw silk is added inside. This process is called “cooking”. After the cooking process the silk is rinsed. Then they are left inside the boiler for dyeing process and the dye is added into the boiler. The dyeing process starts at eight o’clock in the morning by running the boiler. Around 100 kg of silk can be dyed till the evening. The quantity of water used for this process is about 70 – 80 tons.

The process in the boiler starts with dyeing, continues with rinsing and ends with acidification to fix the dye. Once those processes are terminated the silk is taken out of the boiler and is going through the process of wringing. Silk taken into drying areas once wringing is terminated, are dried by coding process as per their color. After the drying process, silk in filament form is gathered together. Apart the areas in the factories where the filaments are wrapped, bobbins are also made in houses as per the occurring need.

2nd Phase

Following the preparation processes in the factory, dried silk are placed on looms. This process is called loom warp. The silk is warped on the looms in accordance with the desired dimensions of the carpet. The chemist performs dye study. The set of filaments necessary for the model of the carpet to be woven are prepared once loom is ready and dye process is completed. The loom and the sets are transported to the workshops for weaving.

3rd Phase

After the manufacturing, carpets sent for weaving are transported back to the factory. The weaving period varies, depending on the carpet dimension, from two months to one year and half. Barcodes are tagged on the carpets in the factory. After the barcode tagging is completed, quality control process starts. After the completion of these two processes the carpets are trimmed to shave off extra particles. After trimming, the carpets are transported to washing area and they are washed with chemicals and soap. Once the washing is completed, they are wringed in 2 phases. The water of small sized carpets is filtered away by spatulas. For big sized carpets water is filtered away in drum presses so that they are not bending. Once the pressing of the carpets is completed, they are dried in drying areas. Once they are dried, hot steam which is directed onto them to soften the carpets for the process called “encapsulation system”. Softened carpets then are ready to be transported into cutting area.

4th Phase

As the carpets submerged into water are bending, the dimensions in length and width are to be leveled. The top and the bottom of the carpets are tried to be even by the help of a punch. After this process, the dimensions of the carpets are kept intact by using wood glue. Following the process of wood glue, another steam process is applied. At last the carpets are subject to a final drying process of eight hours. Dried carpets are sent to maintenance area. The traces of punches used during the leveling of dimensions are fixed by ironing, they are controlled to see whether there is a default or not. Once final controls are performed, the carpets are ready to meet their new owners.