Carpet Yarn Manufacturing Process

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.

Carpet yarn manufacturing process.

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 third and last step in the manufacturing of carpet is the finishing process. The process takes a fiber mass roving reduces the mass through fiber drafting inserts twist for strength and winds the yarn onto a bobbin. Another method continuous dyeing rolls and sprays dyes onto finished carpet.

Soon one loom could make 75 yards 82 m of high quality carpet a day. By 1800 6 8 yards 7 9 m of carpet could be made in a day. Carpet is made in a 3 part 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.

Raw wool has to be converted to yarn through machines where the wool is converted into individual strands which are further spun into yarn. 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. Spinning the yarn itself is a skilled job and one that has created specialist companies serving carpet manufacturers. Is a process that involves opening the bigger and loose lea and wrapping it into tightly wrapped bunch which is smaller in size.

Invented the power loom in 1839 which doubled carpet production. Even today ring spinning makes the widest range of yarn counts with the highest strength. 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. Power looms improved over the years.

All tufted carpets including cut pile start out as a loop. This process is typically a single production line that completes the final stage of the carpet construction. He also invented the first broadloom in 1877. The actual yarn that will be used in the tufting process is dyed beforehand which allows for uniform color.

Still another pre dyeing takes place before the carpet is processed. In the finishing process a coating of latex is applied to both the tufted dyed carpet s primary backing and also to secondary backing.