Our Production

The art of making carpets by hand using the finest materials is cherished and nurtured by Tufenkian. Each carpet is carefully crafted, using methods and techniques that are virtually unchanged from time beyond memory in the service of contemporary design. The glowing variations inherent in natural materials and the human touch are celebrated by Tufenkian in every stage of the process, the result of a commitment to promote individuality and inspiration in all of its production. Truly, each carpet is unique unto itself, created over the course of a journey through a sea of human hands that weave it into existence.

The Tufenkian Production Process is done entirely by hand using similar processes in both Nepal and Armenia. The Tibetan production process is described here:

Shearing

Tibetan sheep are raised by nomads in the Himalayan Mountains, which range from 12,000 to 20,000 feet above sea level. They produce lustrous, resilient, lanolin-rich wool that is considered the finest in the world for rug production.  For Armenian production, sheep are raised in the Caucasus mountains.




Washing

In order to preserve the natural lanolin, personality and character of its fibers, Tufenkian wool is never bleached or scoured. Instead, it is washed gently in local rivers to remove Impurities.







Drying

After the wool is washed, it is moved to the riverbanks or nearby fields to dry naturally in the sun.









Sorting

Tibetan sheep are not bred for uniformity as in other countries.  Therefore, the wool is sorted according to color variations: white, beige, dark brown and black.







Carding

Using a metal-bristled brush, the fibers of the wool are roughly aligned in preparation for hand spinning.









Spinning

Using simple, foot-powered wooden wheels, the wool is spun into yarn.  This process creates many of the beautiful imperfections found in Tufenkian carpets.







Dyeing

Dyeing is done in energy-efficient sealed containers for color control and to save energy.  Swiss Metal Complex dyes are used, which are more consistent in color and will never run or fade, while allowing the natural character of the wool to express itself.





Weaving

The weavers follow the pattern shown on a full-sized graph that hangs in front of them.  There are usually four to five workers for a 9’ x 12’ rug, which is made up of 650,000 to 1.5 million knots and takes an astonishing 3,000 hours of human labor to complete.





Carving

Once the carpet is woven, it is leveled with large shears, and then finely detailed with light carving between colors, adding subtle impact to the carpet design.







Finishing Wash

Tufenkian carpets are either washed in Europe’s premiere washing and finishing facility or in the Tufenkian (Nepal) wash—an environmentally-responsible system developed by Tufenkian in Nepal that, for most carpets, matches the quality of European washing and is unsurpassed in environmental responsibility.

 

 
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