How Carpet is Made

Knocking at the door of all our Albany and Greater Tri-City Area carpet enthusiasts! Here’s a beginner-friendly informational on,

Fibers and filaments! Knotting and weaving!

This cut, that color. That pile, this backing. So much to decide with so little time and we’re already tearing at the seams!

Categories are,

What's in this Tuft?

The basics first.

CAR·PET noun

Pronounced (kaar·puht)

Definition:

Flooring made of thick woven fabric, typically wall to wall.

Most Popular Celebrities: Nylon, Polypropylene, Polyester, and Wool

Can be Found Vacationing in: Rolls, Runners, or Tiles

Age: Speculated to have existed since 5BC, but stardom reached the United States in 1791

Now that we have you briefed, on to the nitty gritty.

There is a war in the carpet world and it is very pretty.

Synthetic vs Natural

On your left, we have our Synthetics.

100% Nylon

Couristan

Heavenly - Sea Salt

Stanton

Finsbury Park - Marine

Oxford Street - Desert

100% Polyester Indoor Outdoor Carpet

** Compared to Nylon

Couristan

Belize - Golden Canary + Chameleon

Tahiti - Chameleon + Golden Canary

100% Polypropylene

** Compared to Nylon

Couristan

Grand Turk -Tidal Lagoon

Olde Chatham - Platinum

Nevis - Morning Sun

And on your right, we have our Natural.

Couristan

Carousel - Mist

Manhattan Beach - Anthracite

CityScape - Gramercy

Now that you know what fiber you want. Let’s get,

In the Loop

There is a 3 step process when manufacturing carpet.

1. Tufting 2. Coloring 3. Sealing

To the tufting machine!

After selecting a fiber, thousands of threaded needles are pushed through a primary backing (often made of polypropylene), creating a loop. If the loops are left as is, Loop Pile Constructed Carpet. If cut, Cut Pile Constructed. Fancy right?

Sometimes you can have both on a carpet, creating some interesting designs.

Gauge, Stitch rate, and Pile height, these ingredients were chosen to make a perfect carpet. And with these ingredients, some popular weaving methods, Axminster, Velvet, and Wilton were born!

To the color wheel!

We are going to focus on 3 primary methods. Solution Dyeing, Continuous Dyeing, and Print Dyeing.

Fibers can be colored before or after tufting.

Pre-dyed carpets are Synthetic and often Solution Dyed, meaning before the fibers are extruded and take shape, color is added to the material in its liquid form.

Post-dyed carpets are Natural and often Continuous Dyed, which involves taking the unfinished carpet in its greige state, running it through an applicator that spreads or sprays dyes, and then steaming the carpet to lock in its new color. A colorful hot tub.

Print Dyeing also takes the unfinished carpet in its greige state and applies color with screen-printing, roller equipment, or inkjet printers to create beautiful patterns and designs. Fresh off the print and press.

All Together Now

The last part of the process, Sealing!

Finally, our tufted and dyed carpet receives a coating of latex on its primary backing. A secondary backing, (typically made of woven polypropylene) is added and receives a coating, then both are sandwiched in a heated press to maintain the thickness and shape of the carpet. Some last minute touches are done, a trim here and there, then our new carpet will get ready for installation.

Although there is still so much more to know about how carpet is made, we just hope you don't have to wonder where to get carpet from!

See you next time at Modern Carpet and Flooring.

Find us here, or Visit our website @ Modern Carpet and Flooring.

See You Soon! (•◡•)/