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PiHue CreationsHandmade rug manufacturer
Our process · sheep to ship

The whole journey, stage by stage.

Every rug moves through the same seven stages. Same order, same discipline, same paperwork — from wool sourced under RWS to a container booked at Nhava Sheva.

Seven stages, one factory floor

From yarn to shipment, under one roof

This is what happens between your artwork arriving and your rug leaving. In the order it actually happens on our floor.

01 · Design

A drawing becomes a map

Your artwork — CAD, sketch or reference photo — is redrawn as a knot map on graph paper. Every square is one knot; every colour is a numbered yarn. Weavers read it like sheet music.

Hands tying knots on a rug in progress
02 · Dye

Yarn takes the colour

Loose yarn hanks are dyed in-house to your approved lab dip, matched to Pantone TPX/TCX or ARS 1400 references. Nothing goes to the loom on faith.

Terracotta-dyed rug drying
03 · Weave

Knot by knot, row by row

On the loom, the rug grows a few centimetres a day. A 250 × 300 cm hand-knotted piece holds several hundred thousand knots — each one tied by a person.

Shuttle on a handloom
04 · Wash

Water opens the pile

Washing brings up the lustre. Wool's natural resilience and soil resistance come forward once the weaving oils are gone.

Herringbone detail after washing
05 · Finish

Shear, stretch, bind

The pile is levelled by mechanical shears; the rug is pinned and stretched to true its shape; edges are hand-bound. Tufted rugs are latex-cured and back-lined.

Finished herringbone drape
06 · QC

Measured, weighed, approved

Size against ±3% tolerance, actual weight ÷ actual area against specified GSM, finish against your approved sample. Only then does it move to packing.

Cream basketweave loop rug
07 · Ship

By air and sea, to your door

Individually rolled, wrapped in moisture-resistant LDPE, labelled with your barcodes. Air out of IGI Delhi, sea out of Nhava Sheva — all Incoterms accepted.

Stack of finished rugs ready for shipment
Start your programme

What is documented at each stage

  • Design. Approved CAD, approved knot map, size specification, quality (GSM / KPSI) specification.
  • Dye. Approved lab dip; dye-house record per bulk lot; transaction certificates for RWS wool / GRS recycled yarn.
  • Weave. Loom register per rug; supervisor sign-off at agreed intervals.
  • Finish. Wash record, latex-cure record (for tufted).
  • QC. Per-piece record of measured size, weight, GSM and finish; comparison against approved sample.
  • Ship. Packing list per rug and per pallet; certificate of origin; export documentation.

More on our three QC gates → · More on how we dye →

Start a programme

Send us your design. Quotation within hours.

A CAD, a sketch or a reference photo is enough — we return pricing, material options and a sampling plan the same working day.