OEM and original manufacturing of rugs

Domestically produced, machine-woven, hand-tufted | RUGMATAG

Domestic production allows us to handle everything from small lots to mass production.
You can create rugs that you can use with confidence, thanks to the product quality that can only be achieved in Japan.

First,you can check the finished product by making a sample of just one piece .

Large-scale automated tufting equipment drives pile at high speed. Rug OEM's mechanical tufting process mass-produces uniform loop pile.

RUGMATAG partners with multiple rug factories in Japan and supports OEM and original rug manufacturing with reliable Japanese technology and quality.

This is the stenciling process, where a special pattern is cut by hand to reproduce the outline of the original rug. This is the design preparation process for OEM rug production.
The process of setting the raw yarn for tufting on the winding machine and preparing for production. A scene from the material management work that supports the quality of domestically produced OEM rugs.
This is the process of applying an adhesive backing evenly to the back of the tufting rug with a roller. This is the finishing process that increases the durability and stability of OEM rugs.

Our OEM Strengths

  • Reliable domestic production for guaranteed quality(antibacterial, odor-resistant, anti-mite processing available)
  • It is possible to label it as "Made in Japan,"which contributes to the brand image.
  • Flexible support from small lots to large-scale mass production
  • Samples can be produced (reprototypes can be made if necessary)

Flow until delivery (overview)

  1. First, consult us
  2. Approximate estimate (free)
  3. Sample production (optional) 45days or more
  4. Ordering and production in domestic factories takes 2.5months or more
  5. delivery of materials

Note: Delivery times may vary depending on the factory's operating status and the content of your request. Details will be provided at the time of consultation.

What is machine weaving?

An automatic tufting machine drives a uniform pile into the base fabric. This is the machine tufting process for rug OEMs, which is suitable for mass production and precision lines.

Machine weaving is a method of making rugs by weaving wool directly into the base fabric using an automatic loom.

Rather than printing on a plain rug, the design is expressed through the color of the yarn itself,resulting ina solid thickness, weight , and three-dimensional feel .

The edges of tufted rugs are sewn with a serger to enhance durability. This is a high-quality finishing process for domestically produced rugs.
Staff at the rug factory operate a PC to check the design data and specifications of an original rug. This is the data management and consultation process for OEM production.

Although it is "machine woven," it is not left entirely to the machine; craftsmen are involved in supervising the manufacturing process and finishing the fabric.

Thisallows us to consistently mass-produce high-quality rugs that arenot only beautiful to look at, but are also carefully finished down to the smallest detail .

What is hand-tufted?

The process in which a craftsman uses a tufting gun to hammer high-density pile into a base fabric fixed to a large frame. This is the production site for a domestic tufting rug OEM.

Hand-tufted fabrics are made by artisans who use a hook gun to weave each strand of yarn into the fabric, creating a one-of-a-kind piece.

A close-up of a craftsman using a tufting gun to hammer pile into the base fabric. The high-precision hand-tufting process for original OEM rugs.

Since it is controlled by hand according to the design, more delicate expressions such as fine lines and complex color changesare possible.

The production process requires time and manual labor, so it is not suitable for mass production, but it allows you to faithfully create the design you envision andproduces a high-quality rug .

RUGMATAG's proposal

At RUGMATAG , we will propose the optimal manufacturing method to meet your needs and applications, such as machine weaving for mass production and cost stability, or hand tufting for delicate expression .  

Flow until delivery

1. First, consult us

Please feel free to contact us.

Staff at the rug factory operate a PC to check the design data and specifications of an original rug. This is the data management and consultation process for OEM production.

If you share the purpose of production, size, quantity, delivery date, design, etc., we will propose the best way to proceed.

Examples of checkpoints to consider when consulting

  • Desired size and purpose (e.g. 80x50cm entrance mat, large rug for exhibition, etc.)
  • Number of sheets you would like to quote (e.g. 50 sheets, 100 sheets, 200 sheets)
  • Desired delivery date (e.g., delivery by month/year 202)
  • Design you would like to manufacture (we accept a wide range of formats including Illustrator, JPEG, PNG, etc. Reproducible line widths are approximately 8mm to 1cm. Please prepare high-resolution data to ensure a clean finish.)
  • Other (budget, specifications, back surface finish, etc.)

Estimated time:Proposal within 1 to 3 business days → If there are no issues, we will provide you with a rough estimate.

2. Optional quote (free)

We will provide you with a quote based on your requirements.

A customer and staff member discussing the actual texture of the product

We will organize prototype costs and mass production unit prices and present them to you in an easy-to-understand manner.

Information

  • Unit price at time of ordering / Price range per lot
  • Costs for sample production
  • Options based on specifications such as yarn used and back finish

Estimated delivery time:2 to 5 business days.

3. Sample production (optional)

We can produce samples from just one piece.

The process of attaching a backing cloth to a tufting rug and pressing it with an iron to finish it off. This is a snapshot of the manufacturing process, capturing the careful post-processing of OEM rugs.

Even first-time users can feel at ease, as the quality and design reproducibility can be checked before mass production.

Recommended for these needs

  • I want to check the color and texture of the actual product.
  • I want to see how the logo and text will be displayed.
  • I want to share the finished product with my client and team.

After checking the sample, if you wish to make any corrections or change specifications, we can also make a new prototype.

*Even when reproducing prototypes, a fee will be charged per sheet.

Estimated time:45 days to 2 months.

4. Order and production at domestic factories

If there are no problems with the sample, we will place a final order.

A craftsman at a rug factory operates a thread winding machine to prepare thread for tufting. A photo of the manufacturing site showing material preparation at a domestic rug OEM.

We can flexibly handle everything from small lots of a few dozen sheets to mass production of several hundred sheets or more.

Advantages of domestic production

  • Stable quality and peace of mind
  • We can also accommodate attaching quality tags and customizing specifications.

Approximate duration:2.5 to 3 months.

5. Delivery

Once completed, your rug will be delivered to the address of your choice.

  • If the order quantity is large, we can also make partial deliveries to suit your schedule.
  • After delivery, we provide after-sales support, including quality control and additional production.

About OEM rugs

With RUGMATAG, you can freely customize the specifications to suit your desired design and purpose.

We can create original rugs with attention to detail, including the material, shape, pile length, and processing method.

■Various specifications to choose from

Yarn: acrylic/wool/nylon

Edge Finish: Overlock/Fold

A close-up of the edge of an ivory-colored tufted rug. It features a uniform locking process with few unevenness, demonstrating the high-quality stitching of OEM rugs.
A close-up of the folded stitching on the back of the tufted rug and the processing of the mesh backing. Details that demonstrate the careful finishing and durable stitching techniques of Japanese OEM rugs.

Pile: Cut/Loop

Pile length: 12-15mm, 20-80mm

Color: Standard colors: Approximately 1,000 colors / Original colors can be ordered

■Examples of machine-woven rugs

・50×80cm/acrylic yarn/cut pile 15mm/folded finish

A rectangular logo rug with the words "Tufting shop RUGMATAG." A design example that allows for OEM production of store mats and rugs with brand logos.
A close-up of an original logo rug with white lettering on a black background, created using the tufting technique. A high-density pile rug, a quality sample of a Japanese OEM rug.

・120×50cm/wool yarn/cut pile 12mm/overlock finish

A rectangular tufting rug with the RUGMATAG logo in the center. This design sample demonstrates that we can produce OEM mats with corporate logos and original rugs for stores.
A close-up of the tufted rug's edge, featuring a brown locking and blue pile combination, and durable edge treatment, a quality detail found on OEM rugs.

・Diameter 60cm / Acrylic yarn / Cut 15mm / Loop 12mm / Overlock finish

A round tufted rug with a large cat face design. This is an OEM production sample of an original design rug that allows for precise lines and multicolor expression.
The details of the cat's eyes are expressed using the tufting technique. The yellow and black three-dimensional loops are distinctive, and this close-up image shows the quality of the high-density tufting OEM, which allows for detailed expression.

・40×30cm/acrylic yarn/cut pile 12mm/overlock finish

An original design rug with a tufting gun motif. This is an example of an OEM tufting rug that uses multi-colored acrylic yarn and can also be customized with logos and illustrations.
Detail of the overlocked edge finish on the back of the tufted rug. This image shows the careful stitching and mesh fabric construction that enhance the durability of OEM rugs.

90 x 90 cm / nylon yarn / cut pile 80 mm / overlock finish

This tufted rug is shaped like a petal. It features a gradient that spreads from purple in the center to pink on the outside, making it an example of an original shaped rug OEM design.
A close-up of the high-density pile of this tufted rug. It has a beautiful pink to purple gradation and a long-pile shaggy finish.

By combining different types of yarn and processing methods, we can achieve a finish that is close to your imagination.

It can be used for a wide range of purposes, from interior mats to large rugs and novelty items.

We will propose the best materials and specifications to suit your desired design and usage scenario.

Please feel free to contact us first.

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