THE RUG'S JOURNEY
Weaving
The production processes of our carpets — made with natural materials and completely traditional methods — are followed constantly. Weaving a carpet on a loom is a delicate process requiring attention and patience. Considering the locations of the villages in this geography, following the process on-site is at least as difficult as weaving itself. We are proud to succeed.
We always invite our customers to our workshops and Malatya centre to experience all our processes. We are happy to share our knowledge, experience, and the reality of production.
Photo: Knot types and weaving tools, 2019, Gerger
Diagram: Turkish (Ghiordes) knotWeaving Techniques
We produce hand-woven carpets on carpet looms using completely traditional methods. We maintain the weaving craft that has continued for centuries in this region and fulfil our social responsibility. Our people keep our culture alive in the oldest settlements of Anatolia.
We pay special attention to each hand-spun weft, warp, yarn, and knot technique. We constantly research antique rug weaving, combining regional techniques with academic literature, our own antique collection, and long years of experience.
We are particularly interested in warp and weft yarns — thickness, softness, and twist. We spin the wefts directly on the loom, a demanding two-day process that is essential for long-term durability. We also cut each knot individually with special scissors, giving our carpets a unique texture and a traditionally rich surface. Thanks to our specially produced weft threads, we achieve a solid, 100% wool weft without any polyester.
Photo: Large loom weaving a Kurdish carpet, 2019, GergerLooms & Equipment
Through past cooperation with Zeytuni, a high-quality loom producer, we have maintained a sufficient stock of looms for about 30 years. We can produce carpets with a maximum width of 8 metres — a scale many manufacturers cannot reach. Our looms are durable and sturdy, preventing the loom breaks that are common problems with large-format carpets.
We use ergonomic equipment for our weavers, and supervisors continuously check the working environment to keep both work safety and carpet quality as the highest priority.
Map: Distribution of Ararat Rugs weaving workshopsWorkshops
Geography is a very challenging factor for us. We have weaving workshops in Adıyaman, Malatya, Diyarbakır, Antep, Siirt, Erzurum, Amasya, Tokat, Iğdır, Van, and Manisa — in villages, mountain villages, city centres, and districts. This distributed structure exists because we seek experienced weavers in each specific region.
Mountain villages can be inaccessible in winter, yet large-format carpets are woven in those areas. Working through geographic challenges to draw on local expertise and tradition is fundamental to how we create.
Photo: Weaving a Kurdish carpet, 2019, GergerOur Weavers
Before opening a new workshop we research the weaving experience of the region thoroughly. We partner with local governments and public education centres, selecting villages and areas with experienced weavers, then send an instructor to build the foundation. Local governments often support us with suitable buildings and incentive programmes for job creation and vocational training.
All of our weavers have full social security and are registered workers. Slavery, child labour, and uninsured employment are legally prohibited in Turkey — and among the issues we care about most. The monthly income of many of our weavers exceeds that of their husbands or fathers, helping raise their social standing and confidence, and deepening regional interest in weaving and traditional arts.
Photo: Ararat ERP softwareERP System
Our ERP software assigns an individual QR code to each carpet, recording where and by whom it is woven, design files, designer, instructor, final controller, bill of materials, and weaving-stage photos — enabling full traceability and research.
Customers who order carpets can follow their carpet's progress in real time. Weavers and controllers in different cities log in simultaneously; production is managed from our Japan and Turkey (Malatya) centres. A dedicated ERP file is opened for each carpet, and design, colour threads, weft and warp specifications, and design printouts are sent directly to the workshop.
The Weaving Process
We would like to share the culture of traditional weaving techniques with our family, who are the main architects of these unique works told on these pages.
