I. DESIGN PROCESS
Design is the process of creating an object to satisfy certain goals, may take into aesthetic, organic, socio-political considerations. The design studio of Boustani Glorious Handicrafts is center of ideation and always open to unheard concepts. We are committed to design high-end, modern Persian rugs based on architectural, functional, minimal, cultural principles of our important markets.
II. Sorting / Scouring
Sheared raw wool of Zagros Mountains region, Iran sort according to the color, length, quality and roughness of fibers then be separated from foreign substances like Lanolin, sweat, urine, vegetable and etc. The method of washing wool with water and Chubak, an Iranian plant or Acanthophyllum has historical background. Chubak absorbs Lanolin and cleans the wool. After washing, wool is placed in a basket and immersed in fresh, smooth, cold water until the wool be totally purified.
III. Hand Spinning
Spinning is an ancient part of textile art. Fibers have spun by hand using spindle, distaff to form yarns for centuries. Hand-spun yarn of wool is the key element of Persian carpet foundation. Hand spinning requires high level skill to make ideal yarn for carpet producing and Iranian nomads with thousands of years backs are skillful enough to do that.
Natural dyes or organic dyes are dyes or colorants derived from plants, minerals or invertebrates. The majority of natural dyes are vegetable dyes from plant sources like berries, bark, leaves and wood and other biological sources such as fungi and lichens. Madder has been used for extracting orange-red dyes, walnut skin for black spectrum, pomegranate for dark red-crimson, weld plant for yellow-greenish, indigo for blue range, cochineal insect for shades of red, pink and purple since ancient times... Yarns dye organically according to the unique colorings of Boustani designs.
V. Weaving by Hand
There are two main weaving methods in Iran: 1. Persian knot, Senneh or Asymmetrical knot 2. Turkish knot or Symmetrical knot. The organic, natural dyed yarns and plot papers are gathered together at warp winded loom according to the designs. Iranian weaver artisans weave modern Persian rugs of Boustani Glorious Handicrafts knot after knot by hand. It takes several months to complete a design entirely and create a significant carpet depends on dimensions, knots per inch, numbers of colors.
During the weaving of a carpet, artisan cuts the yarn a bit longer than planned for the final product and pile has different length. In order to give the carpet a pretty surface, Polishing is required. Polishing is done with a machine like a big beard trimmer by the skilled polisher.
Washing is an extensive, important process in creating a masterpiece. The process includes some main parts such as: 1.Singeing 2.Washing 3.Drying Singeing is the process of burning the extra protruding yarns on the front and backside of the carpets. This process presents a glossy, attractive facing to the carpet. The main reason for washing the carpet, with special detergent, is to remove all remains of dusts, surplus yarns. Simultaneously the colors are being fixed. First, the laid out carpets with large amounts of cold water are rinsed. Then, with the help of a rubber rake or a machine to simplify this work, all the water and detergent is then pressed out from the carpet. This flow must be repeated several times as the carpet is being inspected thoroughly in order to see that the cleanliness are accepted. Afterwards, this is time of drying. Nowadays, special machines are used for drying. Spin drying machine is one of the most common that functions on centrifugal force to forcing the water out by squashing the carpets against the drum wall.
Sunning is one of the last steps of producing a handmade Persian rug after washing process. Modern Persian rugs of Boustani lay out under direct and hot sunlight for 1 to 8 weeks to get the perfect dryness of wool and ideal brightness of surface.
Handmade carpets because of difference of hand spun yarn diameter, hand weaving, soaking during washing process naturally have some curved edges. Stretching process is done on a wooden frame for a few days (1 up to 7 days) to make all sides completely straight.
X. Control and Final Services
In this step, the whole carpet is checked in details thoroughly so that no any damages have occurred during previous steps. The control includes the frontside as well as the backside, the fringes and the sides of the carpet. Folding and sewing by hand the warps of the carpet is done at this time.