After a design is created, the production begins with a single strand of yarn being wound from its cone onto the warping wheel or mill. This continues, one strand at a time, following the instruction for the particular design, until all the warp threads are on the warping rnill. The warp is chained off and put into a bag with the weft yarn for the weavers to complete.
The warps are then sent cottage industry style to one of our many skilled weavers who work at home on large floor looms. The looms are much the same as have been used for thousands of years – shuttle, heddles, reed, treadles.
The warp is put on the loom first and is the foundation of vertical threads that the weft threads (the horizontal threads) are then woven through. It is tied onto the loom one strand at a time, 148 knots for our most common width scarf. The warp is then cranked onto the back beam of the loom. Most warps are eight scarves long or approximately 800 inches. Each scarf is meticulously woven by hand with great attention to detail and then delivered back to the studio.
The scarves then go into the quality control process where every imperfection is corrected. We finish them in our special way in order to create the softest hand available in chenille. The scarves are then trimmed, knotted, fringed, steamed, labeled and packed to ship to our customers.