How to make a carpet?

The word carpet comes from the Italian word carpita, which means 'plucking.' Carpets can be broadly divided into two categories: handmade carpets and mechanical carpets. Natural or synthetic fibers are the main raw materials used to make carpets. Durability, good appearance and low cost are the main factors affecting fiber selection.
The manufacturing process of handmade carpets and machine carpets is different. The handmade rug looks elegant and it will leave a lasting impression on the buyer. In woven carpets, plastic fibers are glued to a sturdy plastic substrate that looks very strong in appearance, but these fibers can easily be disconnected from the substrate. Handcrafted designs are mostly lighter and more durable than mechanical carpets.
Manual carpet manufacturing includes the following processes,
Sort wool for dust and damage
Washing and drying sorted wool
•woolen
Blending (carding) • Spinning blended wool into yarn using a Chalka or spinning machine
• Then dye the yarn. Traditional weavers use natural colors for dyeing. Stained items should be dried in the sun before starting the next step
• These dyed items are sent to a loom for weaving. Most experienced weavers have good knotting speed. Sometimes, depending on the size of the carpet, more than one person will work on the loom.
• After weaving, trim the designs and patterns with scissors. After the finished carpet is washed with water and chemicals, it is dried in the sun for 5-6 days
• After the final touches, pack the carpet in a plastic bag
The different categories of mechanical carpets include woven carpets, needled carpets, knotted carpets, tufted carpets and more. Woven carpets are more expensive than other varieties. Knotted rugs are officially known as complementary weft-cut terry rugs and became popular in the 1970s. The manufacture of knitted rugs is very easy. In the process of making knitted carpets, many needles form loops that are stitched together before starting work. As we all know, knotting is common in almost all carpets and mats.
Needle-punched rugs are very durable rugs and are suitable for hotels and other industrial places, especially indoors. During the manufacturing process, the fibers are locked in a package by using a recompressed needle. It is more similar to a hand hook.
Tufted rugs are common in the indoor world. Most floor rugs are tufted. Its manufacturing process includes different stages. These stages are accomplished through a series of actions. Release finished products for sale at the end of production
Phase 1
• Collect synthetic yarns from various yarn manufacturers and blend them into batches.
• Lubricate these batches and spin them into loose ropes on a carding machine called slivers
• Pull these silvers, straighten and spin them into a single yarn
• Then heat the yarn to 270-280 ° F 132-138 ° F C. This helps the yarn maintain its shape
• After cooling, these yarns are transferred to the tufting machine
Phase 2
• At this stage, dye is applied to the yarn to form a foam
• Treat yarns with special dyes to form colored yarns
• All dyed yarns are steam washed and thoroughly dried
Phase 3
• Turf treatment in stage 3
• Place the yarn on a rod with a string at the rear of the tufting machine and transfer it to a nylon tube that leads directly to the tufting needle.
• Needle backing, pushing the yarn down into a loop.
• To cut the pile, fix the flat hook on a knife operating like a scissors in the opposite direction, and cut the ring. This process is performed by performing multiple puncture needles and 100 darns per minute.
Stage 4
• At this stage, tufted carpets are being dyed. After the dye is applied, the carpet is evaporated to dryness, the excess dye is washed away, then dried and packed into rolls and sent to the finishing department
• To print designs on carpets, tufted carpets go through an embossed roller. The raised portion of the cylinder contains a design that presses color into the carpet. Each cylinder has a different design in different colors.
• After applying the blot and dye, evaporate the carpet to dry, wash away excess dye, then dry the carpet and place on a roll.
Stage 5
The finishing process is in progress at this stage. Brushed and vacuum carpets will be sent to the packaging area. In the packaging section, the carpet is cleanly packed in several plastic trays and stored separately from different manufacturers.

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