On this day, the January 26 2021, which is India's Republic Day, let's learn how the Indian flags are actually made with this incredible video on the subject.
Bengeri in Karnataka is the only place in India where the official Indian flags are manufactured by the Karnataka Khadi Gramodyoyag Samyukta Sangha (KKGSS), the only federation entrusted with this job by the Government of India.
This unit is run entirely by a group of economically backward women, completely dedicated to creating this symbol of national pride that adorn the offices of the Prime Minister, the President, the bureaucrats etc.
This unit is accredited with the ISI certification along with the authorization to sell the national flag across the country. The flags are made exactly according to the BIS guidelines. Any violation of the shapes, size, thread count, strength of yarn or color can land the maker in jail. Made in 9 sizes, each flag follows the ratio of 3:2 and undergo 18 stages of quality check.
The process requires 6 steps: hand spinning, hand weaving, bleaching and dyeing, chakra printing, stitching and toggling.
Khadi or hand spun cloth of cotton, silk or wool are the only materials allowed. There are 2 kinds of khadi used: khadi-bunting for the body and khadi-duck which holds the flag to the pole.
For the khadi duck, there should be exactly 150 threads per square cm, 4 threads per stitch and weigh exactly 205 grams/sqft.
Only after approval of the cloth by BIS, it is separated into 3 lots which are dyed saffron, white and green.
The Ashoka chakra is printed on both sides of the white cloth and the 24 spokes have to be exactly synchronized on both sides. Three pieces of saffron, green and orange cloth are then stitched together according to specifications and the final product is ironed and packed.
The BIS then checks again and only after approval can the flag be sold.
This unmatched dedication towards the flag and the passion for perfection are why even today these are the only women trusted to make the flag.