Introduction: The Journey Behind Every Handmade Rug

Have you ever wondered how a handmade rug is created?

At Bhadohi Carpets House®, every rug is more than just a product — it's a story crafted by skilled artisans using time-honored techniques passed down through generations. From sourcing natural wool to the final finishing touches, each step involves care, patience, and traditional craftsmanship.

In this guide, we walk you through the entire process of how our rugs are made — from raw wool to the final weave — using clear and simple language.

Step 1: Sourcing the Best Natural Wool

Every rug begins with premium-quality wool. We source 100% natural wool, often hand-spun, known for its softness, durability, and natural resistance to dust and fire.

We typically use wool from high-altitude sheep breeds, prized for their strength and unique texture. In some designs, we also use bamboo silk, cotton, or pure silk, depending on the style and use of the rug.

The quality of the wool directly impacts the quality of the finished rug.

Step 2: Hand-Spinning the Wool

Once the wool is cleaned and combed (a process known as carding), it is hand-spun into yarn.

Hand-spinning creates slight variations in texture and thickness — a signature feature of handmade rugs. These natural differences add depth, movement, and character to the final design, unlike the flat and uniform appearance of machine-made rugs.

Step 3: Dyeing the Yarn with Natural Colors

We dye the yarn using plant-based dyes and AZO-free chemical dyes that are safer for your home and the environment.

Our natural color palette includes shades derived from:

• Indigo (for blues)

• Madder root (for reds)

• Pomegranate skin (for golden browns)

• Walnut husk (for rich browns)

After dyeing, the yarn is dried under the sun. This not only helps fix the color but also brings out its natural richness and shine.

Step 4: Designing the Rug

Every rug begins with a design. This can be:

• A traditional floral, tribal, or geometric pattern

• A modern or abstract custom design

• A meaningful cultural or symbolic motif

Designs are usually hand-drawn on graph paper or digitally rendered. These blueprints guide the weavers knot by knot. If you have a custom design, our team can turn your idea into a handmade rug.

Step 5: Setting Up the Loom

Weaving begins by setting up the loom — the structure that holds the rug in place during weaving.

Vertical looms are used for hand-knotted rugs, while horizontal looms are common for flat-weave dhurries. For tufted rugs, we use custom-built tufting frames.

The warp (vertical threads) is stretched tightly on the loom, while the weft (horizontal threads) is woven in — forming the foundation of the rug.

Step 6: Weaving – The Heart of the Rug

This is the most time-consuming and skillful step of rug-making. There are three main weaving techniques we use:

1. Hand-Knotted Rugs:

The most traditional and durable method. Each knot is tied by hand, one at a time. This process can take weeks or even months. We use two major types of knots:

• Persian Knot (Senneh): For fine, intricate detail

• Turkish Knot (Ghiordes): For symmetry and strength

2. Hand-Tufted Rugs:

In this method, yarn is punched into a canvas using a tufting gun. Though faster than knotting, it is still a skilled, handmade technique. It allows for bold and modern designs.

3. Flat-Weave Rugs (Dhurries):
These rugs have no pile and are woven like fabric. They are reversible, lightweight, and perfect for casual or seasonal spaces.

The knot count (KPSI – Knots Per Square Inch) is a key indicator of the rug's quality, detail, and value.

Step 7: Trimming and Pile Finishing

Once weaving is done, the rug is carefully trimmed using sharp shears.

This step helps:

• Define the design clearly

• Set a consistent pile height

• Smooth the surface for an even finish

Trimming brings the design to life with clean outlines and sharp detailing.

Step 8: Washing the Rug

After trimming, the rug goes through a gentle washing process using natural soaps and soft brushes.

This helps:

• Remove any loose fibers or dirt

• Set the colors

• Soften the overall texture

The rug is then sun-dried flat to maintain its shape and color consistency.

Step 9: Finishing Touches – Binding, Fringes, and Inspection

The final step includes:

• Binding the edges to enhance strength

• Adding hand-knotted or braided fringes

• Stretching to ensure the rug lies flat

• Final quality inspection

Only after passing strict quality checks is the rug rolled, packed, and prepared for shipping.

What Makes Bhadohi Carpets House Rugs Unique?

• Handmade by master weavers in Bhadohi, India

• Made from natural wool, plant-based dyes, and traditional methods

• Crafted without machines — only hands, skill, and heart

• Custom rug designs available on request

• Durable and timeless with proper care

Looking for a Custom or Bulk Order?

We make it easy to order rugs tailored to your needs.

• Send us your design idea

• Approve a sample (optional)

• Receive clear delivery timelines

• Get PAN-India and international shipping

WhatsApp us for a quick quote
Email us — we respond within 24–48 hours

From Our Looms to Your Living Room

When you bring home a rug from Bhadohi Carpets House®, you bring home heritage.

Each rug reflects generations of skill, culture, and care. It's not just décor — it's a piece of living art you can walk on. Every weave tells a story. Every thread carries history.