How are Carpets Made

To make the carpeting, the textile materials are formed into pile yarns that are dyed and sewn to a primary backing and then glued to a secondary backing that adds strength and stability to the carpet and separate layer of padding. Woven or non-woven  is most often used to make both layers of backing, although a small percentage of carpet backing is made with jute, a natural fiber woven into coarse fabric. Synthetic rubber latex is the glue that binds the layers together.                   

  How Carpets Is Made

The process of carpet manufacturing has several steps. First, the yarns are tufted, which is the process of weaving the fibers into the primary backing. A tufting machine has 12-foot long rollers and up to 12,000 needles that pull the yarn through the weave of the backing much in the same way a sewing machine would. A small hook grabs each stitch of yarn to create a loop. In carpet lingo, this is called loop pile construction, for obvious reasons. Photoelectric sensors programmed to produce a specific pile height control the size of the loop. Higher pile makes shaggier carpet. In the ‘70s, shag pile was all the rage, but most of the carpet on the market today is low profile pile with uncut loops, which stands up to traffic much better because no cut ends are exposed. It’s easier to clean and less likely to fray or separate from the backing.

Process of how to make carpet

If the carpet is supposed to be tufted, then the actual creation process ends here. If cut pile carpet is being manufactured, however, then the tufted carpet goes through an additional step where the loopers holding the individual pile strands are pulled over sharp knives. This cuts the loops into the individual strands that make up a cut pile carpet.

  • The coloring process may take place at different stages in production, depending on the desired visual effect. As we mentioned earlier, some carpet is put into vats of water after production and boiled while dyes are mixed into the container. This is known as the beck pocess. Another method, continuous dyeing , rolls and sprays dyes onto finished carpet. Still another,pre-dyeing , takes place before the carpet is processed. The actual yarn that will be used in the tufting process is dyed beforehand, which allows for uniform color.
  • Once the carpet is finished, it’s washed, dried and vacuumed. Errant piles are trimmed and then it’s sent on a conveyor belt past a final employee who uses a pile gun to fill in any overlooked bare areas. The carpet is now finished.
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