| The word carpet is originated from an Italian word | | | | Tufted carpets are very common among interior |
| carpita, "carpire" meaning to pluck. Carpets can broadly | | | | world. All most all the floor carpets are tufted carpets. |
| classify into two types-- Handmade carpets and | | | | Its manufacturing process comprises different stages; |
| machine made carpets. Natural or synthetic fibers are | | | | these stages are carried out through a chain of action. |
| the major raw material used for the production of | | | | At the end of the production, finished products are |
| carpets. Durability, good appearance, and low cost are | | | | released for sales |
| the major factors affecting the selection of fibers. | | | | Stage 1 |
| Manufacturing process of hand made carpets and | | | | Synthetic yarns are collected from various yarn |
| machine made carpets are different. Handmade | | | | manufactures and blended together in to a batch. |
| carpets look elegant and it will create long lasting | | | | These batches are lubricated and spun in to loose |
| impression in the minds of buyers. In machine made | | | | ropes called slivers by a carding machine |
| carpets, plastic fibers are pasted in to a strong plastic | | | | These silvers are pulled, straightened and spun in |
| base that looks very strong on the immediate | | | | to single yarn |
| appearance but these fibers may disconnected from | | | | The yarns are then heated in to a temperature of |
| the base very easily. Handmade designs are mostly | | | | 270-280°F 132-138°C. This helps the yarn to |
| light weight and more durable than machine made | | | | maintain its shape |
| carpets. | | | | After cooling these yarns are shifted to the tufting |
| Hand made carpet manufacturing includes the | | | | machines |
| following process, | | | | Stage 2 |
| Wools are sorted to find out dusts, and damages | | | | In this stage dyes are applied to the yarns to make |
| Washing and drying of the sorted wools | | | | a foam |
| Blending of wools (carding) | | | | The yarns are treated with specialized dyes to |
| Blended wools are spun into yarn by using charkha | | | | form a colored yarn |
| or a spinning wheel | | | | All the yarns after dyeing steamed washed and |
| Yarns then put for dying. Traditional weavers are | | | | dries thoroughly |
| using natural colors for dying. Dyed items dried on | | | | Stage 3 |
| sunlight before starting the next process | | | | In stage 3 turfing process undertakes |
| These dyed items are sending to the looms for | | | | Yarn is put on a bar with skewers at the back of |
| weaving. Most of the experienced weavers have | | | | the tufting machine and then shift to a nylon tube that |
| very good speed to do knotting work. Some times, | | | | direct to the tufting needle. |
| depending up on the size of the carpet more than one | | | | The needle does the backing and pushes of the |
| persons will be working in the looms. | | | | yarn down into a loop. |
| When weaving is over, the designs and patterns | | | | For making a cut pile, a flat hook facing the |
| are trimmed with scissors. This trimmed carpets | | | | opposite direction is fixed with a knife that operates |
| washed with water and chemicals and allowed to dry | | | | like a pair of scissors, snipping the loop. This process is |
| in the sunlight for 5-6 days | | | | carried out by a number of needles and l hundred of |
| After giving some final finishing touches the | | | | darns carried out per minute. |
| carpets packed in to plastic bags | | | | Stage 4 |
| Different categories of machine made carpets | | | | In this stage the process of dyeing the tufted |
| includes-woven, needle punched, knotted, tufted and | | | | carpets are taking place. After applying dyes, carpets |
| others. Woven carpets are more expensive than | | | | are steamed, washed off the excess dyes, then dried |
| other varieties. Knotted carpets are formally called as | | | | and packed in to rolls to the finishing department |
| supplementary weft cut-loop pile carpet and were | | | | In order to make printed designs on carpets tufted |
| popular in 1970s. Manufacture of knitted carpets is | | | | carpets passes through embossed cylinders. The |
| very easy. In the process of making knitted carpets, a | | | | elevated portion of cylinders contains designs that |
| number of needles create loops that are stitched | | | | press color into the carpet. Each cylinder has diverse |
| together before starting the work. It is widely noted | | | | design with different colors. |
| that knotting is popular in almost all rugs and mats. | | | | After apply prints and dye, the carpet is steamed, |
| Needle felt carpets are extremely durable carpet | | | | excess dyes are washed off, and the carpet is then |
| suitable for hotels and other industrial establishments | | | | dried and put onto rolls. |
| especially for indoors. During the process of | | | | Stage 5 |
| manufacture, fibers are locked into a pack by using | | | | Finishing processing is carrying out in this stage. |
| needles that are again compressed. It is more similar to | | | | Brushed and vacuumed carpets will be sending to the |
| hand hooking. | | | | packaging sections. |