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Entries in how it's made (1)

Monday
Aug252014

how it's made: handwoven recycled sari rugs

The making of the handwoven recycled sari rugs and runners begins at the core of the rug—the vibrant silk fibers which come from the sari manufacturing industry. This thriving business in India reflects the richness of its culture—and its resourcefulness as it leaves little to waste.

In Bangalore, located in south India, remnants of sarees are sold to companies who segregate it as per the potential use of the materials and a buyer’s needs—and while sarees are made in various parts of India, these lots of remnants are usually a mix of all colors which allows for specific shade requirements to be met in the segregation process.

A control sample helps to guide the color separator and the remainder of the fibers are used to make the yarns of mixed colors—so just about everything is used in the end.

Once the fibers are well organized, it’s then handspun into yarn—the results of this process are yarns with varying thicknesses at random places. In order to have a level of consistency, all the highly uneven count is removed as well as any drastic shade changes.

When enough fibers are gathered and yarn spun, the weaving process begins on a regular vertical loom which is typically used to weave dhurrie or hand-knotted rugs.

During the weaving process, rows of yarns are pressed together using a wooden comb which makes the weaving tighter and more durable.

To secure the weaving and complete the look, the same yarns are used to hand-stitch all of the edges and a final washing completes the process.