Behind the Loom: Custom Rug Process in 90 Days – Step-by-Step
Custom rug process is more than choosing colours and shapes. It’s a structured, time-based journey that moves from raw thread to finished floor piece, often in exactly 90 days. At CarpetsAndRug.com, we walk every client through this timeline to make sure their rug arrives on time and exactly as requested. Here’s a full look into what happens during those three months behind the loom.
Table of Contents
Day 1–5: Design Brief and Material Planning
The custom rug process begins with your input. Whether you provide a reference image, a rough sketch, or just a set of colours and room photos, our design team in Delhi builds out a brief.
What Happens:
- Your inspiration is translated into a rough drawing
- We select between wool, silk, or blended yarns
- Knot density and pile height are discussed (200 to 600 KPSI)
- Dye palette is finalized (natural or chemical dyes)
Timeframe: 2 to 5 days
Output: Final approved rendering with rug size, scale, and knot specs
Day 6–10: Dyeing and Yarn Prep
Once design is locked, we move to yarn preparation. Our dye masters in Bhadohi or Panipat prepare colours in small batches and test for fastness.
What Happens:
- Raw wool/silk is spun and washed
- Dye baths are prepared by hand
- Colour swatches are created and sent for approval (if needed)
- Yarn is dried, wound, and labeled for loom use
Materials Needed:
- Wool: 4–5 kg for 4×6 ft rug
- Silk: 6–7 kg for 4×6 ft rug
- Water-safe dye vats and drying space
Timeframe: 5 days
Output: Color-sorted yarn bundles, ready for knotting
Day 11–15: Graphing and Loom Setup
Next, we turn the approved design into a detailed map. A graph sheet is created with each square showing a single knot.
What Happens:
- CAD or hand-graph made by textile designer
- Loom is cleaned and set up for warp threads
- Warp tension is adjusted for design dimensions
- Knotters are briefed on color order and sequence
Timeframe: 3–5 days
Output: Loom and knotting graph ready to begin weaving
Day 16–70: Knotting the Rug
This is the core of the custom rug process. Every knot is tied by hand around warp threads, line by line. The more dense the rug, the longer this step takes.
| Rug Size | Knot Density | Avg. Completion Time |
|---|---|---|
| 4 × 6 ft | 200 KPSI | 30–35 days |
| 6 × 9 ft | 300 KPSI | 45–50 days |
| 8 × 10 ft | 400 KPSI | 55–60 days |
What Happens:
- Artisans tie rows of knots using a knotting hook
- Wool or silk strands are clipped after each row
- Each inch is checked for tension and symmetry
- Partial photos are shared with clients weekly
Timeframe: 40 to 60 days depending on density
Output: Full knotted rug, still mounted on loom
Day 71–75: Cutting and Shearing
Once knotting is finished, the rug is removed from the loom and goes through its first round of finishing.
What Happens:
- Rug is cut from the loom with reinforced knots at edges
- Excess threads are clipped
- Full rug is laid flat for even trimming
- Pile height is leveled to client’s preference (6–12 mm)
Tools Used:
- Flat shears
- Hand combs
- Large metal rulers
Timeframe: 3–4 days
Output: Raw rug, smooth and pile-balanced
Day 76–80: Washing and Stretching
Washing gives the rug its final softness and helps colours set permanently. Stretching keeps the rug’s edges sharp.
What Happens:
- Cold water soak and gentle brushing
- Neutral soap used to clean yarn residue
- Rug is sun-dried over flat mesh
- Heavy wood frames are used to stretch edges straight
Timeframe: 4–5 days
Output: Clean, softened, straightened rug
Day 81–85: Inspection and Finishing
Every custom rug undergoes a final check before packing.
What Happens:
- Knots are tested for looseness
- Lines are inspected for distortion
- Side binding is tightened or replaced
- Fringes trimmed and evened
- Label is stitched on back
CarpetsAndRug.com shares final photos and a short video before moving to the next step.
Day 86–90: Packing and Shipping
The last step of the custom rug process is safe delivery. We use triple-wrap foam rolls, water-resistant bags, and cardboard tubes for protection.
What Happens:
- Rug is rolled and covered in non-woven cloth
- Moisture pack included for overseas orders
- Tracking ID shared via email
- Home delivery or store pickup is arranged
Timeframe: 2 – 4 days
Output: Rug reaches your doorstep within 90 days
Why 90 Days Is a Reliable Timeline
Some rugs are ready sooner, especially low-density wool pieces. But for most hand-knotted custom rugs, 90 days allows enough time for every step – without cutting corners. Any rush order beyond this requires more artisans and overtime, which increases the cost.
Quality You Can Expect in the 90-Day Custom Rug Process
- Tight knots that don’t shift with foot traffic
- Balanced pile that reflects light evenly
- Correct size within ±1% of spec
- Consistent color with no patchiness or fading
- Proper finishing with solid edges and secure binding
Pricing Factors Within the Process
| Factor | Affects Cost? | Notes |
|---|---|---|
| Rug Size | ✅ | Larger = more knots = higher cost |
| Knot Density | ✅ | 400 KPSI costs 40–60% more than 200 KPSI |
| Material (Silk vs Wool) | ✅ | Silk raises price by 50–70% |
| Design Complexity | ✅ | Floral and shaded designs cost more |
| Colors Used | ✅ | Each colour adds dye and setup time |
| Deadline Rush | ✅ | Rush orders carry up to 25% extra fee |
Common Custom Rug Types Made in 90 Days
- Modern Geometric Rugs (2–3 colours, 200 KPSI)
- Persian-Inspired Rugs (6–8 colours, 300 KPSI)
- Art Deco Custom Rugs (bold forms, sharp outlines, 250–300 KPSI)
- Custom Logo Rugs (for offices and hotels, 200–300 KPSI)
What Makes CarpetsAndRug.com Different
- Weekly updates with photos
- Free swatch kits before ordering
- Transparent pricing with no hidden charges
- Fixed calendar with penalties for delay
- Expert design help from real textile artists
Final Thoughts
The custom rug process takes planning, skilled labour, and honest communication. From day one of the design to day ninety of delivery, every step matters. If you’re looking to order a rug made just for your home or space, knowing this timeline can help you plan well and avoid stress.
CarpetsAndRug.com is here to make sure the experience feels smooth, accurate, and well-supported – one row of knots at a time.
FAQs
1. Is the 90-day custom rug process timeline always fixed?
Usually yes, but if the rug is extra large or highly detailed, it might take up to 120 days. Small or lower-density rugs can finish in 60–70 days.
2. What’s the shortest time a custom rug can be ready?
Some low-density wool rugs can be completed in 45–50 days, but this depends on artisan availability and material stock.
3. Can I request changes during the weaving stage?
Minor changes in colour or border may be possible in the first 10 days. After that, major edits are not allowed because the loom has already started.
4. Is a 90-day custom rug process available for international clients too?
Yes, CarpetsAndRug.com offers the same process with international shipping included. Transit time is an extra 5–10 days depending on the country.
5. Will I be updated during the process?
Yes. You’ll receive email updates with images from the loom at every major step—start of weaving, halfway point, finishing, and packing.
