What is the sequence of carpet making?

the parts of a rug

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The Fundamentals of Rug Making

Although some of the special techniques involved in weaving an Oriental rug may vary from country to country and even from one region to another, the principles of rug-making - from dyeing the yarn to shearing the finished piece - are virtually the same throughout the world and have changed very little over the centuries. Still, a basic understanding of an Oriental rug's construction will be invaluable to you when selecting an Oriental rug.

By and large, most Oriental rugs feature a wool pile, mainly derived from sheep, whose quality depends on factors such as the animal's breed and diet, local climate, and shearing season. After shearing, the wool is washed, carded (i.e., a teasing process that straightens the fibers), and then hand - or machine - spun into yarn. Next, the yarn is dyed in an attractive range of colors and then dried slowly in the sun.

A detailed illustration of the carpet design, most commonly called a cartoon, guides the weavers throughout the entire rug-making process. The design is rendered on graph paper to scale.

Through the ages, looms have remained relatively unchanged. While the most primitive is the nomadic or horizontal loom, the type most generally used today consists of two vertical beams of either wood or metal and two similarly made horizontal beams. The distance between the vertical beams determines the rug's width. Warp threads, usually cotton, are strung between the horizontal beams at a consistent tension. The thickness of the warp threads and the closeness at which they are strung are two of the elements that will determine the fineness of the weave (i.e., knot density) of the carpet that is ultimately woven.

Hand-made V/s Machine-made carpets

It is difficult to make out the difference between a Machine made and a Handmade carpet. But if you know the key points and have an inspective eye then you can separate the two.
More clarity on the differences can be explained in terms of:

• Knots used
• Sides and Ends sewn
• Back of the carpets
• Materials used
• Touch
• Manufacturing process

Knots

Machine-made rugs and carpets are not woven by hand but are loomed by a computer generated system or apparatus. There are no knots in machine-made rugs. Whereas in a hand-made rug, each knot is hand knotted and tied. In machine-made carpets, threads are glued or looped onto a hot latex (plastic) backing which cools and hardens. They show a complete and rigid uniformity in manufacture which transforms into a static design. Machine-made rugs generally lack spontaneity and human touch.

Sides and Ends

In a hand-made or hand-knotted rug, the fringe is 'part' of the rug. The fringe is not sewn on as an extension, as is the case in machine-made rugs. Machine-made rugs always have 'serged' sides or machine stitching on both sides of the rug, as opposed to a hand-knotted which will be irregular and imperfect.

Back

In power loomed or machine-made rugs the stitching on the back is very consistent. They have extremely regular knots and even structure remains identical in all parts of the carpet. On the other hand, in hand-knotted rugs the stitching varies slightly due to different tensions on the wool as people hand-tie the knots. Most hand-made rugs and carpets are covered with a cotton or canvas backing.

MaterialsM

Acrylics and other chemically processed materials are usually used to make machine-made carpets. Hand-knotted rugs and carpets use pure organic wools.

Touch

You can also differentiate a machine-made and hand-made rug simply by touching. If you place one finger on the front of a machine-made rug and your thumb on the back and pinch tightly, the rug will compress greatly and you will feel a sensation going right through one side to the other side. On the other hand, while pinching hand-made rugs you will feel much more body and substance.

Have you ever wondered how carpet is made? While it may not sound like the most popular topic of conversation, it's actually pretty interesting. And knowing exactly how it's made should be considered important since it's a material you're going to be living with, and on for a long time. So, let's begin!

How is a Carpet Made?

That beautiful plush sea of carpet that's keeping your living room floor nice and soft actually starts off as just a bunch of loose strands of fibers called staples. Which leads us to the first step, which is called tufting.

Tufting

These staples are weaved into the primary backing. The backing is usually made of a woven polypropylene which provides a nice base cloth to hold the yarn in place while the tufting happens. And to help you imagine this step even clearer, the machine is about 12 feet wide and looks like a very large sewing machine.

It has anywhere from 800 to 2,000 needles working to pull the yarn through the primary backing material. As the needles penetrate the backing, a small hook, called the looper, grabs the yarn and hold it in place. This process creates what's called loop pile construction.

Dyeing

The second step is the application of the dye. The carpet is taken through two dyeing methods. The first method is called yarn dyeing. This is when the color is applied to the yarn before the tufting process. The second method is simply called carpet dyeing. This is when the carpet is dyed after the tufting. The advantages of both of these methods are the color consistencies, large lot sizes and uniformity.

Finishing Process

The third step is the finishing process. This process is typically a single production line that completes the final stage of the carpet construction. During this last step, a coating of latex is applied to both the tufted, dyed carpet's primary backing and the secondary backing. These two parts are squeezed together in a large heated press, where they're held firmly to preserve their shape.

Shearing Process

Then there's the fourth step, the shearing process. This includes removing all of the little loose ends and fibers that might have been created during the tufting process.

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Inspection

Finally, each carpet is carefully inspected for color uniformity and any other possible manufacturer defects before it's rolled, wrapped and shipped to its happy new owner.

Alternative Steps in the Carpet Making Process

While those are the simple carpet process steps, there are alternative steps since there are different kinds of carpet materials and styles.

Cut and Loop Construction

For instance, in some carpet styles go through the cut and loop construction. What happens is the looper rocks back against a knife, where the small loops of yarn are cut, creating what we call a cut pile carpet. The length of these cut pieces of yarn is referred to as the pile height, and is basically the distance between the looper and the primary backing. These precision cuts are controlled by a computer, and at times creates a recognizable pattern on the surface of the carpet.

There are also other carpet dyeing methods that are used, each producing a unique end result.

Beck/Batch Dyeing

The first technique, often referred to as Beck, or batch dyeing, involves stitching the ends of the carpet together, and then running the tufted carpet loop through the large vats of dye and water for several hours.

Continuous Dyeing

Continuous dyeing is a similar process to Beck dyeing, but it involves running the carpet through several processes in addition to just the dye application. Continuous dyeing applies the color directly to the carpet face by spraying or printing. This process is also used to create multicolor or patterned effects in the carpet.

Screen Printing

Screen printing is another common method of carpet coloring, where color is applied through anywhere from one to as many as eight silk-screens.

So, that's the process of how carpet is made. The right amount of knowledge can be as functional and practical as the carpet itself. We also hope that this information leads you to a better understanding of how this beautiful and versatile flooring material is created, and helps your carpet shopping experience with one of our design experts!

References

• How Carpet is Made (). https//www.builddirect.com/learning-center/flooring/how-carpet-is-made
• The Carpet and Rug Institute (). https://carpet-rug.org/about-us/history-of-carpet
• How is Carpet Made? ().https://home.howstuffworks.com/home-improvement/home-diy/flooring/how-is-carpet-made.htm
• Carpet - How It's Made. https://strathmoredesign.com/carpethowitsmade

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