How Carpet Is Made

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The carpet that is made today is a mix of old world

craftsmanship and a touch of 21st century innovation.

By combining the two, carpet is able to become the

household feature that we all know and love – and

get tired of cleaning.

Carpet can be manufactured in one of two ways;

weaving or tufting. Carpets that are woven are

primarily wool and are very durable, and very

expensive as well. The woven carpet types can be

hand produced, as it has been for centuries, or by

machine. No matter what method is chosen, the same

procedures are followed.

The yarn for the carpet is woven through or around

vertical fibers known as warps, and then locked

into place with horizontal strands known as wefts.

The woven carpets can utilize a variety of colors

as well to create intricate patterns in the

highest quality of carpets.

Tufting machines can also be utilized as well, as

they use computers to determine the patterns, styles,

construction, and density. No longer does someone

have to do everything by hand or mentally, as the

tufting machines will take all of the guesswork out

and make things easy on the operator.

Once the fibers have been locked into place, the

carpet is dyed using a variety of methods that

will create patterns or effects. For cut pile

carpets, the final stage is stretched,

cutting the pile loops. This is an important

stage, as it will determine the softness and

feel of the carpet.

The carpet will also receive a secondary stretch

backing as well to give it stability and allow

it to be stretched during the installation

process. Most of the carpets of this day and

age will receive stain protection as well, which

happens during the manufacturing phase.

The way that a carpet is made will greatly affect

how the carpet is installed. In the past, the

creation of carpet was a very complicated

process, as there were no computers or technology

to do most of the work. Back then, it was all

done by hand. The carpets were great, although

there wasn’t any colors or textures that we

have to choose from today.

The carpet manufacturers of today have a lot of

technology at their disposal, which makes life

at the plants easy. Operators can watch and

operate machines to do a lot of the work, which

makes their job a lot easier.

The continuous fibers found with carpet are heat

set and twisted at the mill to give a tightly

twisted product that is commonly found with

frieze carpets. This type of yarn is less

bulky although it will hold its shape for a long

period of time, which is great for those who

don’t like to replace their carpet every couple

of years.

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