How is Carpet Made?

Posted on: December 5th, 2019 by The Carpet Guys
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With over 30 years of experience in the flooring industry, The Carpet Guys want to share how carpet is made.  Check out this simple, informational blog to help you understand the process.

Creating the Fibers

First, the fibers made.  Nylon and/or polyester pellets are melted and smoothed out. The synthetic fibers go through several machines to straighten them, gather them into neat rows, and create large bands.

These bands are combined and stretched to create a thread.  Next, these threads are rolled onto spools.  Two threads are twisted to create one stronger, thicker thread. Then, two of those threads are twisted together to make a 2-ply yarn.  This 2-ply yarn goes through a heat-setting machine to ensure it doesn’t come untwisted.

Tufting

After the 2-ply yarn is set, 1440 spools of yarn are used to create a standard-sized roll of carpet.  The yarn feeds into the tufting machine through plastic tubes.  These tubes deliver the yarn to 1440 tufting needles.  At last, the tufting needles push the yarn through a canvas-type backing to produce a loop. Cut loops are “plush” carpet. Un-cut, it’s a “loop” style, like Berber.

Dyeing

Following the production of the base, they dye the carpet.  Also called piece-dyeing, there are a few different methods.

  • For intricate designs, a “printer-like” machine forces streams of dye onto the fibers of the carpet.
  • Or they soak the carpet in a dye bath at approximately 100 degrees Celsius for four hours.
  • Another dying option is using an autoclave.  This machine uses heat and pressure to dye the fibers in a fraction of the time it takes with other methods.

In contrast to piece-dyeing is solution-dyeing. This is when the dye is added to melted polyester or nylon pellets.  For that reason, the color goes all the way through the fiber, rather than just on top.

To learn more about dyeing, check out our other blog The Carrot and Radish Diagram

Adding the Backing

Finally, they add the carpet backing.  Water-Based glue is applied to the back of the canvas, “marrying” the glue and canvas in a special machine.  This lock’s the carpet fibers in place.  The machine evaporates the water in the glue so the carpet can be rolled and cut.

The Carpet Guys Get Factory-Direct Pricing

The Carpet Guys order straight from the manufacturer.  As a result, we get a bigger discount.  In addition, we can offer our customers next-day installation from our stocked warehouse.  In order to get carpet at discount prices, Be Wise, Call The Carpet Guys at 855-4-MY-GUYS (855-469-4897) or fill out our Free In-Home Estimate form.

 
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