Silk dominates the textile industry with its sensuousness, glamour and lustre. Silk was discovered some 4500 years back, but the tradition of silk weaving now mainly deals in traditional wears and sarees. Sarees made of silk sports lightweight, resilience and offers choices to women to express their inner you in vibrant colors. If you are one of the silk admirers, then you should definite purchase one to grace an occasion scheduled ahead.
Many people including the celebrities are fascinated about silk saree weaving technique. The Bollywood Actress Vidya Balan was so fascinated with the silk saree making process that she urged her designer Guarang Shah to teach her the process. Gaurang kept her request and drove Vidya to his weaver.
The weavers of the village greeted Vidya with a warm welcome. She was amazed to hear the rhythmic sound of bamboo looms. Vidya went speechless when she threads tied around the weft and warp with immaculate precision. She enjoyed a lot when she was coached by Shah’s weaver to weave the threads.
Before you buy sarees online, will you not be interested to learn about the manufacturing process?
The Manufacturing Process Begins with Warping
Weavers purchase yarns from cooperative societies. After procurement, the yarns undergo dyeing process where the desired color is added. Finally, yarns are sent for warping.
The weavers make bamboo reed and dent it with care. The installation part is crucial as the reed controls the way threads are lifted.
After the reed has been erected, the silk yarn is subjected to twists, so that leases can be formed. The leases are fed to the slots of the reed. After the completion of the denting process, eight rods are made of bamboo is attached four shafts and healds are fastened with threading through warp ends. Each warp end is plucked and looped around the heald eye.
In this process, the existing ends of the reed-heald setup are joined with the ends of the new warp by twisting. This is the pre-weaving process.
Addition of Leases
After the completion of the piecing process, the weaver straightens the wrap. Lease rods are inserted to determine the length of the saree. The leases are inserted and marking is carried out with a damp kumkum and bamboo stick. The warp is rolled on a metal cylinder. The warp beam is then fitted to the loom.
Raised pit loom is used for weaving silk saree. Before the loom is set into operation, every part of the loom is checked thoroughly. The warp beam is fitted firmly and the warp is stretched out. The ends of border pattern warp are hung by using nylon threads that are connected with the patterning box.
Metal cylinders hold the weft yarn. The weft yarn is wound as the weaving process advances.
Saree Manufacturing Process
The body of the silk saree is woven in a plain weave. The cross-border is woven with the deployment of rib weave. For attaining best results, the saree is soaked in water for the entire night and is woven in wet condition next morning. The advantage of weaving saree in wet condition is that it prevents saree from tangling or coiling. A gumming solution is applied after every few inches of weaving. This allows saree to stiffen.
Once the saree is woven, it is subjected to folding. The beam is removed and the saree is subjected to sunlight so that the gum and the starch could stiffen. When the saree dries out completely, it is folded in a specific pattern. The folded saree is then stacked and wrapped with fabric for distribution in the market.
These are the steps, which weavers follow to manufacture silk sarees.