Island Weaver’s Master Craftsmanship Process
Because our goal is contribute to your successful project, we first begin by learning as much as we can about your carpeting needs. Knowing styles, budget, colors, shape of rooms, and traffic patterns are just the beginning; on large projects we also will identify how goods are to be moved through corridors, identify the best places to seam together large carpets, positioning of furniture in the room.
Communicating through email we can quickly provide you with color drawings of your carpet. Once the drawings have been approved we will provide you with a preproduction sample using best color/material matches on hand. As the design is being approved, the yarn requirements are quantified and matches to your color needs will be selected from our 1600 Chromo-tone Colors. In case the color you need is not in our standards, we will be happy to match from a swatch or Pantone color chart.
When all the details of your carpet have been determined, using full-scale templates our artist will transfer your design to a canvas that is slightly larger than the required carpet. The canvas is then stretched onto a tufting frame where our craftsmen begin inserting cut or loop piles from the underside (Back Side) of the canvas, one color at a time. On large complex carpets, it is not uncommon to have as many as ten expert craftsmen working simultaneously their own element of the design.
Our carpets are constantly inspected to ensure the correct placement of color, correct stitch rate, and to ensure that the stitches have been placed directly on the canvas. After a final inspection the yarn is set in place by first stretching the carpet canvas horizontally (Underside up), then applying cotton webbing, and applying a coat of latex to anchor the tufts in place.
For carpets that will be used in “Wall to Wall” installations the edges of the carpet will be left over-sized. For carpets that will be used as rugs, the edges of the carpet are hemmed or over locked with the same base yarn.
Once the latex has dried, the carpet is turned face up and inspected again. For carpets that have cut pile designs the lengths of the tufts are cropped to a uniform height, which will produce a velvety texture. On loop pile carpets, new textures can be added by sheering the loops. By carving the carpet additional patterns, shape, depth, definition, and texture can be added.
In every stage of our carpet production, Island Weaver’s has installed quality control processes that comply with the latest ISO 9002 standards. Our process is painstaking, but our clients can rest assured that their carpet will be of the highest quality.
In Your Palace
Once your carpet arrives to you location, Island Weavers can arrange for local experts to install your carpet.