Carpeting is a way to embellish your decor and make it look extraordinary. Carpets are getting more and more noticeable due to their exceptional features and they are the necessity of every home decor. This is because they enhance the appearance of every place and perk up your decor.
But the thing is have you ever wondered how are carpets made? You don’t have to blame yourself if you don’t know about the manufacturing of carpets. Just by running your fingers over the carpet, you can learn quite a bit about it. You’ll find out whether the pile that is the exposed top part of the carpet is composed of individual strands that are either cut pile or tufted.
You can also determine the density or face weight of the pile. You can also determine that what you assumed was a monochromatic carpet can actually be the result of an optical illusion where several distinct dyes blend to create a tone that looks like one colour.
However, here the question is whether they are made with a material that is similar to woven fabric. Many ways and techniques are available through which you can make carpets. But here we will discuss the three leading steps that include the manufacturing of carpets so that you can easily make them.
Read more : How is Carpet Measured: Unveiling the Process
Have a look at the following steps for How are Carpets Made?
The first step to manufacturing the carpet is tufting which is the most ancient method of creating carpets. By weaving the synthetic fiber into a primary backing material you can start the process of tufting.
It is a type of weaving technique where the strips of cloths, threads, and yarns are driven through a base material like tufting cloth and glued together for strongholds. This primary backing material is made of woven polypropylene and its basic purpose is to provide a base cloth to hold the yarn in place when the tufting process happens.
The machine for tufting looks like a big sewing machine. This machine has 800 to 2000 needles to pull the yarn through the backing material. The size of this machine is 12 feet wide and the needles penetrate the backing. It often comes with a small hook known as a looper that grabs the yarn and holds it in its right place. This procedure is known as loop pile construction.
2. Application of Dye
The next step for how are carpets made includes the process of dying. During carpet manufacturing, the carpet goes through two dyeing procedures, and here carpet is taken through the first dyeing process.
The first method of dyeing the carpet is known as pre-dyeing or yarn dyeing. This is because here the color is applied to the yarn before tufting. There are multiple advantages of yarn dyeing. Some of these advantages are side-by-side color consistency, large size, and uniformity.
In the second method of dyeing, the color is applied to the yarn after it has been tufted. This method is known as carpet dyeing and the best part is that there are multiple ways to do this.
3. The Finishing Process
The next step for How are Carpets Made comprises different easy steps. As the name says this is the last process of carpet manufacturing. In this process, a latex coating is applied to both the dyed and tufted carpet’s primary backing.
It is also known as the secondary backing that is made of woven polypropylene material. Both parts of the carpet are squeezed together through a large heated process, the carpet is held firmly to keep the shape right.
This stage of manufacturing the carpet also includes shearing. In this process, all the little loose ends are removed and projecting fibers are created. Carpets are then dried after the raw washing and embossing In the finishing process.
Now, inspect each carpet carefully to check the uniformity of color and also check the other manufacturing defects before the carpet is rolled, wrapped, and shipped.
4. Shearing Process
The fourth step in how are carpets made is the shearing process. This includes removing all of the little loose ends and uneven height of the pile and fuzzies. This process restores the colour of the carpet and provides clarity. You can use a sharp knife or scissors but you can also buy electric carpet shearing tools to even the surface of the carpet. They are easy to buy but you don’t need to buy them if you cannot afford them.
Each carpet is inspected carefully for examining colour uniformity, pile density, and durability. Experts check if there are any other possible manufacturer defects.
Then the carpets are rolled, wrapped carefully in their packings, and shipped to their desired new owner.
Alternative Steps in the Carpet Making Process
There are different types of carpet styles and fabric materials. We discussed the simple steps for the manufacturing of carpet. Let’s have a look at these alternative steps.
Cut and Loop Construction
Some carpet styles go through cut and loop construction for instance. It is a process in which loop fibers are combined with the cut or straight ones. The small loops of yarn are cut and create a cut pile carpet.
The length of these cut pieces of yarn is then referred to as the pile density or height and is basically the distance between the looper and the primary backing of the carpet. These precision cuts are then controlled by using a computer and they create a recognizable pattern on the surface of the carpet.
Different carpet dyeing methods are used nowadays and each produces a unique and specified end result.
The first technique in this process is often referred to as beck or batch dyeing. Beck dying is directed as a continuous process that is used to dye long fabric pieces of several thousand yards. While batch dying involves dying textile material. In this method, manufacturers stitch the ends of the carpet together and then pass the tufted carpet loop through the large vats of dye and water. The dying process takes up several hours to complete.
Screen printing is the common method of coloring carpets. In this method, the color is applied through anywhere from eight silk screens or one to as many. So, that’s how carpet is made after passing through various easy and time taking steps. Having the proper knowledge is as functional and practical as the carpet itself. We also hope that this information leads you to a better insight that how this beautiful and versatile flooring solution is created and helps to embellish your decor with one of the design experts.
Quality control is the most important step as you inspect every piece that is tufted. Manufacturers check every piece from every dimension and carpet resistance to wear, fade-out resistance, heat resistance, the pile of the yarn and their density, padding of carpet and their backing, strength and durability, foot traffic and vacuuming or maintenance, and quality of the fabric is tested. After a thorough inspection of each and everything, carpets are made available to the market for customers.
Whether you just simply want to know the process of carpet making or you want to manufacture the carpets yourself, you can adapt these above simple steps to accomplish your task. This simple yet brief guide will help you to find your answer about the manufacturing of carpets that how are carpets made, and their size or longevity including prices. So carefully read all the information if you want to have a carpet for your floors.