Post details: How carpets are made

02/03/05

Permalink 02:12:46 am, Categories: Articles, 400 words   English (US)

How carpets are made


MANUFACTURING PROCESSES

There are two ways to make carpeting today.

Weaving
Weaving has been used to make carpeting for centuries. Today, they are available as hand-made or machine made. Weaving takes longer, but results in a finished product that is extremely durable. The yarns are woven through or around vertical strands of fiber called warps. The yarns are then locked into place with horizontal strands called wefts. The carpet or rug may be hand knotted around the warps or woven around the warps. They come in a variety of patterns and allows for individual placement of colors in yarns for the finest quality looks and specialized designs. Most of our woven products use wool for the face fiber and are of the finest quality.

Tufting
Approximately 90% of carpeting today is manufactured by tufting. While weaving attaches the fiber to fabric strands, tufting involves hooking the fabric by needle into a pre-existing fabric structure, usually by machines at high speeds. Four processes are included in the making of tufted carpets: processing the fiber, tufting, dyeing and finishing.

1. Processing. At this stage, many of the pattern effects, styling, and construction are created. The denser the construction, the better the performance. This stage determines the type of carpet style (frieze, Berber loop, cable, cut/uncut, etc.). The tufting machines of today use sophisticated computers to give the carpet just about any look imaginable. The carpets of today are better constructed and use a better fiber than in the past.

2. Dyeing: If the carpet is not using a solution-dyed fiber, it will need to be dyed using several different methods. This stage also gives the carpet color, pattern in color, multicolor, heather, and flecks as well as solids.

3. Finishing. The final stage in manufacturing is finishing, where the carpeting is sheered for the best finish (higher twist products finish the best here). The carpet also receives a secondary backing. Here the poly or action back is applied to give the carpet dimensional stability and allow it to be stretched over a pad. Some of our better quality carpets come with a high pic backing. This process is the same as that used in polypropylene construction but with a much tighter weave.

4. Stain treating. All carpets today are treated for stain protection. There are only a couple of apartment grade products which do not come with stain protection.

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