Flat strips of paper are twisted into strong round yarn by machines. At this stage, they’re all brown or white, and have to be wound into loose skeins in preparation for the dyeing process.
The yarn is placed in a huge perforated steel drum, which is then immersed into the alkaline, temperature-controlled dye vat. Dye masters watch this process carefully and make adjustments as needed to achieve the perfect hues.
Hundreds of cones of yarn are fed into the weaving loom, where a machine performs the work. Despite the automation, a person is always watching over the operation to ensure quality.
The rugs are trimmed to size and strips of cotton edging are sewn all around them to protect the edges. They are then rolled up and wrapped for transport to their new home.
Sourced from Germany, this wool is made from New Zealand sheep. It provides a dense, soothingly fuzzy feel. It also tends to produce rugs with varying nuances of colour thanks to the use of different sheeps’ wool fibres in the blend.
First used in Finland to make up for other materials’ shortages after World War II, paper is a flatter option than wool or cotton. That said, it remains nicely springy and is made from sturdy Swedish brown paper or US white paper. To make it, a single flat strip of paper is twisted tightly until it becomes yarn.
This is a flat tube of knitted cotton fibre from Estonia, made of 80% cotton and 20% recycled polyester. The tubular structure gives it volume and softness. When woven, its flattened shape also lets it twist and turn in a way that adds variety to the appearance of the weave.
German polyester is used for the warp, or the yarn that runs lengthwise across all of the rugs. Thin, strong, and flexible, it may not always be visible in the rugs. However, it’s integral to their strength and integrity.