How Sarelli Interiors Textiles Ensures Quality in Custom Rugs
Sarelli Interiors Textiles ensures quality in custom rugs through a strict 40-point inspection protocol that measures yarn integrity, knot density, color accuracy, and dimensional stability. Our quality assurance team evaluates every custom rug against specific commercial and residential performance metrics before the rug leaves our Italian facility.
Material Inspection and Yarn Preparation Standards
The quality control process for Sarelli custom rugs begins with raw material verification, where technicians measure wool fiber thickness and silk weight to guarantee structural integrity. Sarelli rejects any yarn batches that fail to meet our strict baseline requirements for tensile strength and moisture content.
Sarelli sources New Zealand wool with a fiber diameter between 33 and 37 microns to ensure maximum resilience in high-traffic areas. For silk components, inspectors verify that the pure mulberry silk measures at least 19 momme. The yarn dyeing process requires a moisture content below 15 percent before the yarn enters the dye vats. Technicians test the raw materials for colorfastness using ISO 105-B02 standards. Clients selecting specific fibers through our Rug Materials guide receive documentation confirming these exact fiber specifications.
Production Monitoring for Hand-Tufted and Knotted Rugs
Sarelli production managers conduct daily inspections during the weaving and tufting phases to verify that the knot count and pile height match the approved technical drawings. Continuous monitoring prevents structural defects and ensures the final rug achieves the specified weight and density.
For hand-knotted pieces, quality control specialists count the knots per square inch (KPSI) using a specialized magnifying loupe. Sarelli requires a minimum of 100 KPSI for standard residential designs and up to 400 KPSI for intricate silk patterns. During Hand-Tufted Production, technicians measure the pile height with digital calipers to maintain a strict tolerance of plus or minus 1 millimeter across the entire surface. A standard Sarelli hand-tufted wool rug must weigh a minimum of 4.5 kilograms per square meter. The production team logs these measurements into a central tracking system every 48 hours.
Color Matching and Dye Lot Verification
Sarelli color specialists use digital spectrophotometers to compare the dyed yarn against the approved client strike-offs and standard ARS color poms. This scientific color verification guarantees that the final custom rug matches the original design intent with zero visible chromatic deviation.
The Sarelli dye house processes yarn in batches up to 50 kilograms to maintain absolute color consistency across large custom orders. Technicians evaluate the dyed yarn under D65 standard daylight illuminants to detect any metamerism. Sarelli requires a Delta E color difference value of less than 1.0 between the approved sample and the final production yarn. Clients reviewing options in the Colors & Samples program receive physical strike-offs measuring 30 by 30 centimeters. Sarelli archives a 50-gram sample of every custom dye lot for 10 years to facilitate exact color matching for future replacement orders.
Final Dimensional and Durability Testing
The final inspection phase subjects the completed custom rug to rigorous physical testing, including dimensional verification, pile binding strength checks, and commercial fire rating compliance. Sarelli issues a formal certificate of authenticity only after the rug passes all physical and regulatory tests.
Sarelli inspectors measure the finished rug dimensions, allowing a maximum variance of 2 percent from the specified length and width. For commercial projects, technicians submit rug samples to independent laboratories for EN 13501-1 fire classification testing. Sarelli commercial rugs must achieve a minimum Cfl-s1 fire rating. The quality team also performs a tuft bind test using a dynamometer, requiring a minimum extraction force of 30 Newtons to pull a single tuft from the backing. Customers ordering through our Bespoke Customization service receive a detailed inspection report listing these exact test results prior to shipping.
