The Sarelli custom rug creation process requires four distinct phases: initial design consultation, technical CAD rendering, physical strike-off approval, and final hand-crafted production. Sarelli Interiors Textiles completes this entire bespoke manufacturing cycle within 8 to 12 weeks for standard residential and commercial orders.
Initial design consultation and technical drawing specifications
The design phase translates client concepts into precise manufacturing blueprints using specialized textile software. Sarelli designers convert submitted artwork, Pantone color codes, or architectural floor plans into digital renderings within 48 to 72 hours of the initial request.
Clients begin the Bespoke Customization process by submitting visual references or exact dimensions to the Sarelli design team. The Sarelli design team maps the requested pattern to the exact millimeter scale of the final rug. The digital rendering includes specific color mapping using the ARS 1200 color system. The technical drawing specifies the exact pile height, which typically ranges from 10mm for hand-loomed flat weaves to 16mm for plush cut-pile designs.
Material selection and physical sampling timelines
Material selection determines the final texture, durability, and light reflection of the custom rug. Sarelli produces a 30×30 centimeter physical sample, known as a strike-off, within 14 to 21 days after the client approves the digital CAD drawing.
Clients choose from premium Rug Materials including New Zealand wool, bamboo silk, and pure botanical Tencel. A standard luxury residential rug contains a blend of 70 percent New Zealand wool and 30 percent silk, yielding a total weight of 3500 GSM (grams per square meter). Sarelli ships the physical strike-off directly to the client or architectural firm for final approval. The physical sample allows clients to verify the exact dye lots and fiber luster under specific project lighting conditions. Clients can also review standard color tufts in the Sarelli Showroom before requesting a custom strike-off.
Hand-tufted production and quality control metrics
The manufacturing phase involves stretching the primary canvas over a vertical frame and manually inserting yarn using specialized pneumatic tools. Sarelli allocates 6 to 8 weeks for the physical production of a standard 3×4 meter hand-tufted rug.
The Hand-Tufted Production process requires skilled technicians to follow the printed canvas blueprint precisely. Technicians shoot the dyed yarn through the canvas backing at a density of 80 to 100 tufts per square inch. Once the tufting process concludes, workers apply a natural latex adhesive to the reverse side to secure the yarn. The rug then undergoes a rigorous shearing process to ensure a perfectly level pile height across the entire surface area.
Sarelli quality control inspectors examine the finished piece under 5000K daylight bulbs to verify color accuracy against the approved strike-off. The final inspection includes a 25-point checklist covering edge binding integrity, dimensional accuracy within a 2 percent tolerance, and total weight verification.
| Production Phase | Average Duration | Client Deliverable |
|---|---|---|
| CAD Design & Color Mapping | 48 to 72 hours | Digital PDF Rendering |
| Strike-off Production | 14 to 21 days | 30×30 cm Physical Sample |
| Main Manufacturing | 6 to 8 weeks | Finished Custom Rug |
| Quality Control & Shipping | 5 to 7 days | Export-Ready Packaged Rug |
