Carpet Yarn Manufacturing Process

Power looms improved over the years.

Carpet yarn manufacturing process.

1 tufting begins with weaving the synthetic or staple fiber into a primary backing material usually made of woven polypropylene main value is to provide a base cloth to hold the yarn while. Invented the power loom in 1839 which doubled carpet production. Carpet is made in a 3 part process. He also invented the first broadloom in 1877.

Main sources of embodied water and carbon in carpets this section identifies the main pre manufacturing and manufacturing processes responsible for the bulk of energy and water use in carpet n. In the finishing process a coating of latex is applied to both the tufted dyed carpet s primary backing and also to secondary backing. Raw wool has to be converted to yarn through machines where the wool is converted into individual strands which are further spun into yarn. Even today ring spinning makes the widest range of yarn counts with the highest strength.

Another method continuous dyeing rolls and sprays dyes onto finished carpet. All carpets are made from either natural fibers man made fibers or a combination of both that are spun into yarn that is then woven or tufted into the finished article to be found in carpet retailers throughout the globe. The process takes a fiber mass roving reduces the mass through fiber drafting inserts twist for strength and winds the yarn onto a bobbin. By 1800 6 8 yards 7 9 m of carpet could be made in a day.

During the carpet manufacturing process once carpet yarn is stitched into place the carpet is dyed using a variety of methods that will create solids patterns or effects. Fibre or yarn dyed on commission. Soon one loom could make 75 yards 82 m of high quality carpet a day. The actual yarn that will be used in the tufting process is dyed beforehand which allows for uniform color.

All tufted carpets including cut pile start out as a loop. For cut pile carpet the loops are cut during the tufting process. Spinning the yarn itself is a skilled job and one that has created specialist companies serving carpet manufacturers. Once the carpet is finished it s washed dried and vacuumed.

From wool to yarn before the actual carpet weaving process takes place in the carpet factory there is a lot that goes in making the yarn. This process is typically a single production line that completes the final stage of the carpet construction.