Once the colours were finalised, Mary was introduced to Farim, who demonstrated the next steps in the block-printing process.
Firstly, each colour needs a dye tray. These trays are built up in layers: a wire mesh at the base, then jute, then different woven fabrics on top. These layers control how much dye rises to the surface and how it transfers onto the wooden block.
The setup changes depending on the block design. More detailed blocks need a tighter top fabric so the dye reaches all the small carved lines, while simpler, bolder prints use looser fabrics, allowing the dye to spread more freely.
Adjusting these layers changes how the dye sits on the block and directly affects the final appearance of the print.
Mary and Farim tested each block to ensure the carvings were accurate, an essential step since most of our patterns rely on multiple blocks that must fit together seamlessly. Each block is placed using small carved markers, then firmly pressed down by hand. Even missing the marker by a few millimetres can disrupt the entire print. Watching Farim work showed the level of focus required, although he described it as almost meditative once in rhythm.
After printing, the fabric must be cured so the colours set. Unlike many studios that rely on extensive washing, our production partner uses steam to fix the dyes. This uses less water and avoids additional chemicals.
Because we use azo-free and GOTS-certified dyes, when the fabric is eventually washed, the rinse water contains no harmful chemicals and is reused for agricultural fields.
This approach to water use and waste management was a deciding factor when we chose to partner with this block-printing studio.
It was a long but very informative day in the studio. Getting things right early helps avoid misprints and reduces our fabric waste.
Seeing this work firsthand also deepens our connection to the people behind our products. Meeting artisans like Ravi and Farim matters a lot to us. Managing production from afar without knowing the makers wouldn’t feel right, and what we learn from them gives us a clearer sense of what’s possible for future designs.
Mary’s visit reinforced that our printing partners’ technical expertise and thoughtful approach align with our priorities: careful craftsmanship, responsible resource use, and minimising environmental impact.