How is carpet made?
When most people think of carpets, they picture the luxurious floor coverings in high-end homes and businesses. But few people know how these carpets are made. This blog post will look at the carpet-making process and discuss some of the critical factors that influence its quality. We will also explore the different types of carpets that are available on the market today. So if you’re interested in learning more about this important flooring option, keep reading!
Two Different Carpet Cuts
To better understand the carpet manufacturing process, make sure you familiarize yourself with the primary types of carpet cuts. While carpet varies widely in cut, color, texture, and material, most carpet types fall into one of two categories: tufted carpet and cut carpet.
Tufted carpet refers to a carpet pile that has been looped but not cut. In other words, the top of each fiber is looped back down and then woven into the backing (more on that in a moment). Think of it as embroidery, where the needle takes the thread up through the bottom of the fabric and then pushes it back down on the other side. Tufted carpet is easy to maintain and works great in high-traffic homes and businesses.
For cut carpet, imagine the same piece of embroidery but finished. Once finished, imagine dragging a sharp knife over the fabric so that each embroidered loop “bursts” and the cut fabric forms a thick, plush shag. Cut pile carpet typically feels much more luxurious than tufted carpet and provides some extra texture. However, cut carpet gets dirty and worn much quicker than tufted carpet.
How is Carpet Manufactured?
Of course, the first step of the carpet-making process is creating the carpet fibers woven into one piece. The carpet pile can be wool, velvet, nylon, etc. Additionally, there must be a design plan in place for the finished product. Once the material and the design have been determined, the carpet is produced through the following process.
If you have ever seen carpet ripped up or laid down, you know that it is more than just a piece of woven fabric. Rather, the carpet fibers must be backed by a sturdy mat. This is known as carpet backing.
Tufting is the process of looping the carpet pile through the backing. In the modern world, this is done using a 12-foot rolling machine with thousands of needles weaving the loops in and out. Special sensors carefully monitor the height of the pile to ensure everything is tight and even. If the carpet design is tufted, the finished piece of carpet goes from the tufting machine to being dyed.
Cutting comes after tufting if you are going for that design. Sharp blades are gently run over the tufted carpet loops, doubling the number of surface fibers on the piece of carpet. This process produces a plushier carpet that feels great on the feet.
Once the carpet has been woven and taken off the machine, it is time to add the dye and design. Dyeing can be done using several different methods. One method is to boil each section of carpet in a large vat of dye for several hours. Screen-print refers to loading the carpet on a rolling machine; a large stencil is placed over the carpet, and the dye is sprayed or pressed on over the stencil.
If any of the processes listed above are skimmed over, then your carpet is going to suffer as a result. To ensure that you are getting the best carpet possible for your home, you want to ensure that it comes from a trusted servicer. Finding a company that does not cut corners is a must if you want a quality carpet.
Looking for a great carpet?
At Bloomsburg Carpet, we pride ourselves on producing environmentally sustainable, beautiful, high-end rugs and carpets of all types and materials. Whether you are a homeowner searching for a CRI-certified rug or a business owner looking to improve your building, we can help. Contact us for assistance regarding either commercial or residential carpeting.