Manufacturing

Thorndike Mills Heirloom Craftsmanship – New Possibilities

 

Click on the thumbnails below to watch our rug manufacturing operations:
Take a tour of our
manufacturing process
As seen on Chronicle

 

The days of identifying your first Sunday suit or your Dad’s winter overcoat in the braided rug you walk on are fleeting. And certainly, most of today’s Moms and grandmothers don’t have the time to strip fabric and hand-braid it like their ancestors once did. But, rest-assured, Thorndike Mills braids its rugs with these vivid memories.  Our high quality braided rugs are manufactured with the words "authentic" and "reproduction" in mind…plus, "possibilities."

We don’t confine ourselves to thinking back to Colonial times and manufacturing reproductions that only fit with Early American or Colonial décor.  (That’s old school.) The many braided rug colors and styles we offer will enhance and complement many decors, from Craftsman, Country Cottage, Beach House, Traditional and eclectic decorating styles. Oh, the possibilities. Visit our gallery and see for yourself.

That’s why we provide strict specifications to our cloth manufacturers—as well as our yarn suppliers, because we only want our braided rugs to be of the highest quality possible—so they fit in with any lifestyle, are durable for families (including man’s best friend, Fido), and still enhance almost any décor.

 

 

The Cloth Braid Process

(Our Signature Braid)

 

 

 


Thorndike Mills™ is unique in the fact, that we are the only manufacture that features a true cloth braided rug construction.  The next best option to this, would be an actual hand made rug.

 

Thorndike Mills™ only purchases cloth materials that are custom made according to our rigorous standards and specifications allowing us complete control of quality and color.

 

     
 
Bolts of cloth are cut into fabric strips of precise widths using modern cutting equipment.
 

 

These fabric strips are hand guided and spliced together to create color designs.  The newly spliced cloth is sewn on an angle to ensure strong seams, and is then folded and blind stitched  to ensure stability and performance.

 

 

 

 

The braid is now ready to be stitched into the finished product.

 

Perhaps, the most critical phase of the manufacturing process is the actual stitching of the rug. A well trained and experienced stitcher will ensure that the rug is correctly stitched and tensioned properly so that it will lay flat even after professional cleaning.  The size will be exact with normal manufacturing tolerances.

 

 

 

 

The Yarn Braid Process

(Our Classic Braid)

 

Braided Rugs constructed from yarn is the typical construction of a commercially made braided rug in today’s market.  The difference with a Thorndike Yarn Constructed braid vs. the competition is how we buy our raw materials, and the superior standards we implement to produce the highest quality finished product.
 

 

Only the finest carpet yarns are used in the manufacturing of our yarn braided rugs.
         
 

 

Thorndike begins with an extra step to initially maximize the durability of your yarn-braided rug.  Yarn spools of 2-ply strength of specified fibers are woven into strips of fabric.  This is different from how most yarn braids are constructed, as this step is not even done.
 



The woven yarn is hand wound by skilled craftsmen in preparation for braiding.

Filler is essential in a Yarn Braided Rug.  Thorndike uses only the finest filler, which is made for this specific purpose.  The spools of woven yarn are braided around a natural/synthetic fiber core.

 

After the woven yarn is wound onto spools, it is placed onto the braiding machines. This is where the process of creating the braid and inserting the natural filler takes place.
 

 

The finished Braid is sorted in barrels by color,  ready to take to a stitcher to be sewn into a rug.
 

 

 

Rugs are sewn on large air tables by Skilled New England Artisans.

 

Every Braided Rug is Hand Inspected
before leaving our Facility.
 

 

 

 

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