Sarelli Rug Manufacturing Locations and Facilities
Sarelli Interiors Textiles manufactures rugs and carpets in two primary locations: the company-owned Sarelli atelier in Modena, Italy, and GoodWeave-certified partner facilities in India and Nepal. The Modena atelier handles hand-tufted and Aubusson flat-weave production, while the South Asian facilities specialize in traditional hand-knotted techniques.
The Sarelli Modena Atelier Production Specifications
The Sarelli Modena atelier spans 1,200 square meters and employs 14 master artisans. The Modena facility produces Hand-Tufted Production pieces using pneumatic tufting guns operating at 800 stitches per minute. Sarelli artisans in Italy create custom carpets with a pile density reaching 4,500 grams per square meter (GSM). The Italian production line requires 120 to 150 hours of manual labor per 10 square meters of finished carpet. The Modena atelier houses custom-built stretching frames that accommodate carpets up to 6 meters wide and 12 meters long without requiring visible seams. Sarelli artisans apply a secondary cotton canvas backing using a specialized adhesive that cures at 24 degrees Celsius over a 72-hour period. The Modena team also executes Aubusson flat-weave techniques, achieving a warp density of 12 threads per centimeter. Sarelli managers inspect every Italian-made rug under 5,000 Kelvin daylight-balanced LED lighting before the rug receives a final batch ID. Clients visiting the Showroom can view the Modena production samples directly.
GoodWeave-Certified Partner Facilities in India and Nepal
Sarelli Interiors Textiles partners with three GoodWeave-certified workshops located in Kathmandu, Nepal, and Varanasi, India. The Kathmandu facility specializes in Tibetan knot techniques, producing hand-knotted rugs with densities ranging from 60 to 150 knots per square inch (KPSI). The Varanasi workshop focuses on Persian knot structures, achieving densities up to 300 KPSI for intricate silk designs. Sarelli requires all South Asian partner facilities to undergo biannual independent audits to verify fair labor practices and environmental compliance. The Indian and Nepalese workshops process raw Rug Materials including New Zealand wool and Chinese mulberry silk graded at 6A quality. The Nepalese artisans wash the finished hand-knotted rugs using a traditional paddle-washing technique with purified water, which softens the wool fibers and enhances the natural sheen of the silk. The washing process removes residual dye particles and stabilizes the carpet dimensions, ensuring the rug will not shrink during future professional cleanings. Sarelli logistics teams import the finished hand-knotted pieces from South Asia to the Modena warehouse for final quality assurance.
Custom Carpet Manufacturers Quality Control Processes
Sarelli operates as one of the leading custom carpet manufacturers by enforcing a 40-point quality control checklist on every finished textile. Sarelli inspectors measure pile height variance, color fastness under ISO 105-B02 standards, and dimensional stability before any carpet leaves the facility.
The Sarelli quality assurance protocol dictates that pile height must not deviate by more than 1.5 millimeters across a 4-meter span. Sarelli technicians test color fastness by exposing dyed yarn samples to 40 hours of continuous xenon arc light. The testing process ensures the Colors & Samples approved by the client match the final delivered product with a Delta E value of less than 1.0. Sarelli applies a natural latex backing to all hand-tufted carpets, curing the latex at 22 degrees Celsius for 48 hours to prevent off-gassing. The Sarelli quality control team rejects any carpet showing more than 2 percent dimensional shrinkage after steam cleaning tests.
Rug Manufacturing Lead Times and Shipping Logistics
The rug manufacturing timeline depends strictly on the chosen technique and the physical dimensions of the piece. Sarelli completes hand-tufted carpets in the Modena atelier within 6 to 8 weeks from the date of final design approval. Hand-knotted rugs produced in the Nepalese and Indian facilities require 16 to 24 weeks for completion because the artisans tie each knot manually. Sarelli ships finished Rugs & Carpets globally using specialized cylindrical packaging that prevents pile crushing. The packaging consists of a rigid cardboard core measuring 15 centimeters in diameter, wrapped in 200-micron waterproof polyethylene film. Sarelli logistics coordinators arrange air freight for urgent deliveries, which costs approximately 12 to 15 EUR per kilogram depending on the destination. Sea freight options take 25 to 35 days and reduce shipping costs by 60 percent compared to air transport.
Custom Rug Manufacturers Material Sourcing
Sarelli stands apart from other custom rug manufacturers by sourcing raw fibers directly from origin countries. Sarelli purchases 100 percent pure New Zealand wool, which features a fiber diameter of 33 to 35 microns, ensuring maximum durability for high-traffic areas. The Sarelli procurement team sources botanical silk (viscose) from sustainable European forestry operations, specifying a denier count of 120D/40F for optimal light reflection. Clients requesting Bespoke Customization can select blends of wool and silk in precise ratios, such as 70 percent wool and 30 percent silk. Sarelli dyes all yarns in small batches of 50 kilograms using metal-free Swiss reactive dyes. The dyeing process consumes 40 liters of water per kilogram of yarn, and Sarelli partner facilities treat 100 percent of the wastewater through reverse osmosis systems before discharge. Sarelli documents these material specifications in the technical dossier provided for all commercial Projects.
Sarelli Rugs Collection Inventory and Availability
While Sarelli focuses heavily on made-to-order production, the company also maintains a curated inventory of finished pieces. The Rugs Collection includes 45 distinct designs available for immediate dispatch from the Modena warehouse. Sarelli stocks these ready-to-ship carpets in three standard sizes: 200 by 300 centimeters, 250 by 350 centimeters, and 300 by 400 centimeters. The pre-manufactured inventory features a standard pile height of 12 millimeters and a total weight of 3,800 GSM. Sarelli warehouse staff package the ready-to-ship collection items within 24 hours of order confirmation. The standard packaging includes a moisture-absorbing silica gel packet weighing 250 grams to protect the natural fibers during transit. Sarelli updates the available collection inventory quarterly, adding 5 to 8 new designs based on current interior design specifications. Customers can reserve collection pieces by submitting a formal request through the Sarelli Contact portal.
