If you have seen Weavers sitting in their looms, peddling the footer and moving the shuttle back and forth, and think thats how a saree is made? Then you must have not seen the complete picture.
It takes 3-5 days, handful of resources and a lot of men power to create one saree. Check out all the process and behind the scenes of a single saree.
1. Dyeing

The scoured yarns are bleached first, rinsed and then dyed with vat dyes of different colors. They adjust the intensity of the color to get different tints and shades. There are about 6-7 men who works here.
2. Drying

The yarns are then hung and air dried in a huge open space.
3. Winding

Winding of yarns for warp are done through a big charkha, called Jantaram. At a time, yarns for 36 sarees can be winded for warp. It takes about 1and a half-2 days to complete one set. The charkha is manually rotated clockwise and anti-clockwise to achieve the 8 shape.

Whereas winding of yarns for weft are done in Ratnam. This is a small charkha which is commonly found in every weaver’s house. They convert the han yarns into small reel, to fit it into shutting.
4. Street Sizing

Sizing is the starching of yarns to make it crisp and strong. ‘Ganji’, which is the boiled rice water is used as the starching agent. Firstly, the 36 yards of yarns are fixed into a wooden stand, folded in half. Then, the starch is sprayed with spray noozle and distributed evenly with a brush, this process is repeated until the desired result is achieved.
5. Street Warping

After sizing, the warp yarns are then rolled into a roller called ‘bonda’ for the further process of weaving.
However, for the yarns that doesn’t need starching, warping is done separately in the same setting.
6. Weaving

When the weaver gets the ‘bonda’, warped yarns, they set it into their looms, the yarns are passed through combs and are hold by white threads called ‘jaal’, the ends are then tied to other roll, where after wefting, the sarees are kept.
The weft yarn reels are inserted into the shuttle, and the weaving process takes place. It takes 1-2 days to complete one saree.
Which is then finished, scanned for defects, packed and is ready to deliver to you.