Carpet manufacturing process




 

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Carpets are primarily loom woven. Although previously carpets and rugs were created using hand looms, the present carpets and rugs are manufactured on machine looms. Some rugs are still woven on hand looms. These handwoven carpets, depending on the quality of the rug, command a premium price.

The mechanized manufacturing of carpets is primarily done by one of the following three processes.

  • Woven
  • Tufted
  • Needlefelt

 


Woven
Machine woven carpets are manufactured on massive looms that weave together the muti-colored yarns and backing of the carpet. These newer generation looms help in creating a carpet that has intricate designs and provide the carpet a long life.
Though these carpets are comparatively expensive, the woven carpets have a luxurious look and feel.

Tufted
Created on tufting machines, tufted carpets are popular in the domestic and office sectors. Usually single colored, thfted carpets are created by using a single colored yarn. If a non-colored yarn is used the carpets are dyed to the required color.
The tufting process is faster as compared to the woven one and it involves tufting of the yarn in the pre-woven base of the carpet. This process involves pushing of the yarns in the base of the carpet which are held in place by loops. Some of the present day tufted carpets also come with basic geometric designs.
Tufted carpets are cheaper in price and fall in the low to medium category cost range.

Needlefelt
Needlefelt carpets are created using synthetic material on technologically advanced machines. They involve producing of electrostatic attraction between the individual fibers and result in forming a highly durable carpet which is used in hotels, offices and other locations where the traffic is high.

Some other types of carpet manufacturing process are:
Flat weave
Flat weave carpets are produced by interlocking of the vertical and the horizontal threads. This technique does not involve knotting of the threads and the process involves using the warp as the foundation and the wefts are woven through the warps. These carpets are called flat weaves as the threads are not knotted and hence it creates a flat carpet.
Some of the common types of flat weaves are Kilim, Soumak, plain weave, tapestry weave and Brocade.

Hooked rug
Hooked rug, a handicraft, is created by pulling strips of cloth through the mesh of a fabric.