Most of us walk on carpets in our own homes, out and about, and even in the office, every single day without ever considering what exactly we are stood on.
Sure, the concept of where it is that carpets come from isn’t exactly the most exciting for most people, but for those with a curious mind, how carpets are manufactured is something that may well have crossed your mind from time to time.
Fear not, we are here to answer all your questions.
Over the years, like with pretty much every man made or man shaped product, the manufacturing process of carpets has changed significantly, and the carpets produced today are very different than those used over a thousand years ago.
That said, they do the same job, and the innovation of these early peoples laid the groundwork for the luxurious wool and polypropylene Allfloors carpets available in our showroom to this day.
OK, enough waffle, lets get right into the action and look at how carpet is manufactured in the modern age, and the process that goes into creating the warm and cosy carpets that may well be underneath you at this very point in time.
What is the process of creating carpets?
Nowadays, the most common carpet making process involved creating closed loops of fibre from a long spool with a needle that weaves the fibres through the underside of the carpet backing.
As the needle returns back through the backing, the fibres are held in place by something that is known as a looper, creating a loop (imaginative name right!).
This process is pretty speedy these days thanks to the rise of manufacturing technology, but things certainly haven’t always been this way. Think how long it must have taken when carpets were being created manually.
In some cases, the loops that are created in this process are simply left as they are and installed with loops intact. This is known as a tufted carpet. However, in order to create a cut pile carpet where each strand of pile stands individually, an additional step is required where the loops are pulled over sharp knives to break the loops.
What about the colour?
The design and colour of your carpet can be created at various different stages of the process, depending on the material that is being used and the colour you desired
In general, however, the carpet is dyed, either by placing it into a vat of water and boiling the dye in, or by spraying the dye onto the carpet.
Both these methods are conducted after the carpet has been constructed, however, some carpets may be pre-dyed prior to the looping process. This creates a more uniform and consistent colour.
Once the carpet has been dried, is it cut into the required lengths and bang, it can now be distributed to carpet fitting companies across the world and find its way into a property near you in the not too distant future. Visit us now to learn more.