CARPET INDUSTRY

Establishment
In late 19th century, a carpet trading concern was established by a noble and versatile business merchant named Sheikh Din Muhammad. Later his all four sons carried forward and expanded carpets business and enhanced its prestige and goodwill by dint of relentless working, pragmatic planning and good business governance. Soon after the emergence of Pakistan, one of the four brothers, Sheikh Ahmed Hassan founded Lahore Carpet Manufacturing Co. in 1949. This new company carried on the tradition of excellence and firmly established its reputation as producer of high quality carpets with an identity of their own. Later the family business was converted into a corporate business. Which is being now run by familys third generation with fourth one is on its doorsteps. During its 58-year journey, the company crossed many milestones in its unrelenting efforts in achieving excellence in quality of products and processes.

Differential Characteristics

We own all departments of production & finishing under one roof except weaving. Having manufacturing experience of more than 55 years. We are introducing "Modern Management Techniques" of integrated approach to achieve the maximum output in minimum time. Own personal "Raw Material Resources" We have "Walk In Management" so in case of any problem directors and managers have direct access to the work at any time.

Innovative Manner

We have R&D department, which is continuously working on developing new collection design, processes, material and introducing new trends according to the requirements and establishing the existing ones. As the natural colors attracts attention and fascinate more than the artificial colors so we have our own vegetable dying unit, tremendously working for natural colors.

Vision Statement
"To become a leading manufacturer of the world by creating attractive and unique designs adopting innovative techniques and endeavoring to produce for carpet loving people".

Mission Statement
"To be known as trend setters in the carpet industry catering to the customers demand by reading the wishes in their eyes and turning them into reality before they give their thoughts as expression".

Core Values

The first and the foremost thing for us is our commitment. If we commit, then we do it with righteous and virtuous manner. We are keen to develop strong relationship to endorse healthy environment for business.

Latif Enterprises Produce the Best Quality hand made Carpets from Pakistan at the most Competitive Prices. One of the largest Companies of Pakistan dealing in Hand Made Carpet was established 35 years ago. The company is well known all over the world for making of hand-knotted carpets in wide variety of designs and colors. With its vertical and horizontal integration the company has all facilities available for making of best quality hand made carpets. Manufacturing Process Hand-made carpets are technically very different from machine-made carpets. As it is quite relevant from their names, hand-made carpets are woven by hands while machine-made carpets undergo treatments by various machines Process of hand-made carpets Process of machine-made carpets HAND MADE CARPETS Hand-made carpets are traditionally more expensive than those made by machines. Though there are several carpet-making methods, including braiding, hand tying (or hand knotting), hooking, shearing and tufting, the most common of these are braiding and hand knotting. Braided carpets are done by connecting or tying strips of fabrics together. Hand tying or hand-knotting are usually done on rugs. Countries that are known to produce beautifully crafted hand-knotted rugs include Spain, Portugal, India, Pakistan, Turkey, Afghanistan and Japan (among others). Hand-knotted rugs are descendants of Oriental

Rugs and can be made in any shape, size, coloured or design.

Process The process that creates a hand-made/hand-knotted carpet can be explained as under: Wool sorting & Washing Wool is either imported or is bought from nearby markets and is carefully sorted to pick out unwanted particles. Wool often carries dust, grease which is removed by washing it thoroughly and is then sun dried for two-three days. The Tibetan wool has a strong good fibre length is imported in scoured form, good lustre and a high resilient value. The New Zealand wool is of 36 micron, 100 mm barb length and is identified as type 128. British wool meeting regulatory standards have also started being available in the market. Carding The carding process allows the fibre stand to flow smoothly when spinning. This is also the stage for blending different wools and to ascertain the ratio of different origins. Traditionally, carding was performed by hand and machine carding was introduced when the industry grew. However hand carded product is still available if a customer so desires. Spinning The carded wool is spun into yarn by using a charkha or a spinning wheel. The thickness of the yarn depends on the quality of the carpet and generally a 3 ply yarn is used. Dyeing

The traditional pot dyeing method has been largely replaced by machine dyeing in closed Chambers. Dyes containing harmful substances such as AZO are banned and dye-stuffs from renowned international manufacturers are used. These dyes have a high degree of fastness. Depending on the weather, the dyed yarn has to be dried in the sunlight for one to three days. Pot dyeing and vegetable (natural) dyeing are still being used by some manufacturers. Carpet Knotting Knotting is an art. Weavers who weave on a regular basis have a very good speed in knotting. They tend to develop this speed over a span of time. One or more weavers work on a loom depending on the size of the carpet. Each weaver makes individual knots row after row. The designs are chartered out on a graph and a map reader or another weaver instructs the graphic designs to the ones knotting the carpet. The dyed yarn is made into balls and scissors, iron rod, levers, comb beaters are used as tools. Trimming The finished carpet is taken off from the loom and the designs & patterns are trimmed by scissors. Washing and Drying The trimmed carpet is washed with the fresh water & chemicals. The washed carpet is dried in the sunlight up to four or five days. Final Touches

The dried carpets are given final touches by re-trimming and stretching, where ever necessary. The purpose is to bring the fabric woven in level at the surface. Packing All washed carpets are rolled and wrapped in polythene sheet and is sealed at each end. Again, it is wrapped in Hessian cloth and sewn. Generally, around 14m2 are packed in each bale. Payment Export proceeds must be received through an irrevocable letter of credit (L/C) or advance payment

Machine-made carpets are tufted, woven, knitted, flocked or needlepunched. Most commonly tufting is used for machine-made carpets. Tufted carpets are made on machines where the yarn is stitched through a pre-constructed backing to form a loop or a tuft. To hold the loops in place, the back side of the carpet is coated with latex. Tufting is the most inexpensive and fastest ways to manufacture a rug. Weavers can also control the tuft size making it possible to create carpets with varying patterns or surface textures. There are three kinds of woven carpets: Velvet, Wilton and Axminster. Velvet is the least complicated of construction methods. Velvet carpets usually come in one solid coloured and a tweed effect may be noticed. Wilton carpets are more intricate. These are manufactured by using a Jacquard loom which can hold up to six different coloured of yarns. The Axminster method of weaving carpets produces the most elaborate designs with a wide variety of coloured. Knitted carpets are faster to make. In knitting, several sets of needles create loops and these are stitched together before the backing is applied. Knitted carpets come in solid or tweed and the pile may be of

the same size or of varying heights. Flocked carpets are similar to Velvet carpets in appearance. They have a dense cut pile of short fibres that are imbedded into an adhesive-coated backing. Needle-punching is similar to hand-hooking. Formerly used for indoor-outdoor carpets, this process is now being used for carpets that are only meant to be placed indoors as well. In needle-punching, fibres are locked into a packing by using hooked needles, which are further compressed. The Manufacturing Process The process of manufacturing tufted carpets can be explained in the following steps: Step 1: Preparing the yarn First, the synthetic yarns arrive at the carpet manufacturer either in staple fibre form or in bulk continuous filament form The staple fibres, which are an average of 7 inches (18 cm) long are generally loose and are individual strands that arrive in bales. Several bales are blended together into one batch in a hopper. Then, these strands are lubricated and are spun into long, loose ropes called slivers by a carding machine. The slivers are then pulled, straightened, and spun into single yarn that is wound onto spools. Both the single-ply staple fibres (now spun into filament) and the bulk continuous filament is then twisted together to form thicker twoply yarn suitable for tufting. The yarns are then steamed to bulk them, and then heated to 270280F (132-138C). This heat setting causes the yarn to maintain its shape by fixing its twist. After cooling, these yarns are wound onto tubes and transported to the tufting machines.

Step 2: Dyeing the yarn Generally, most carpets are dyed after tufting yet sometimes the

yarns are dyed first. The methods include putting 500-1,000 pounds (227-455 kg) of fibre into pressurized vats through which treated dyes are circulated, or passing the fibre continuously through the bath, or passing skeins of yarn through the vat of dye. The yarn can also be put on forms, and the heated dyes can then be forced under pressure from inside the forms to coloured the yarn. Another method passes the yarn through printing rollers, while yet another involves knitting the yarn onto a form that is then printed with dyes before the yarn is unraveled. All yarn that has been dyed is then steamed, washed, and dried. Step3: Tufting the carpet At this stage, the yarn is put on a creel (a bar with skewers) behind the tufting machine and then fed into a nylon tube that leads to the tufting needle. The needle pierces the primary backing and pushes the yarn down into a loop. Photoelectric sensors control how deeply the needles plunge into the backing, so the height of the loops can be controlled. A looper, or flat hook, seizes and releases the loop of yarn while the needle pulls back up; the backing is shifted forward and the needle once more pierces the backing further on. Inorder to make a cut pile, a looper facing the opposite direction is fitted with a knife that acts like a pair of scissors, snipping the loop. This process is carried out by several hundred needles (up to 1,200 across the 12 foot [3.7 ml width), and several hundred rows of stitches are carried out per minute. Thus, one tufting machine can produce several hundred square yards of carpets per day. Step 4: Dyeing the tufted carpet Solid coloured carpeting: For this carpet of several standard roll lengths is sewn together to make a continuous roll, which is then fed into a vat. The vat is filled with water, which is first heated before dyes and chemicals are mixed in. The mixture is then slowly brought to a boil and cooked for four hours approx.

 Another method of making solid coloured carpet is to sew several rows together to make one continuous roll, which is then fed under rods that bleed the coloured into the pile. After dyeing, the carpet is then steamed to fix the coloured, excess coloured is washed off, and the carpet is dried and put on a roll. Printed Carpets: Inorder to make printed carpet of various designs, white carpet passes under screens in which holes in the desired pattern have been cut. The desired coloured is squeezed through the holes in the screen, and the carpet is advanced 36 inches (91 cm) to a different screen that applies a new coloured in a different design through the screen. Up to eight coloureds can be applied with this method. Another method of dyeing printed carpet is to pass it under embossed cylinders that have raised portions in a design that press colour into the carpet. Each cylinder provides a different design for a different coloured. After dyeing, the printed carpet is steamed, excess dyes are washed off, and the carpet is then dried and put onto rolls to go to the finishing department. Step 5: Finishing the carpet The ends of the dyed carpet are first sewn together to form a continuous belt. This belt is then rolled under a dispenser that spreads a coating of latex onto the bottom of the carpet. At the same time, a strong secondary backing is also coated with latex. Both of these are then rolled onto a marriage roller, which forms them into a sandwich and seals them together. The carpet is then placed in an oven to cure the latex. The completed carpet is then steamed, brushed, vacuumed, and run through a machine that clips off any tufts that rise above its uniform surface. The carpet is then rolled into 120 foot (37 m) lengths that are then packaged in strong plastic and shipped to either the carpet manufacturer's inventory warehouse or to a retail carpet store. Hand-made V/s Machine-made carpets

Carpet is a textile floor covering that is fixed to the floor surface and extends wall to wall. Such a textile floor covering is manufactured in two ways: hand-made or machine-made. One of the most prominent differences between hand-made and machine-made carpets is that the former holds a valuable impression. The other main difference between these two types of rugs is the actual manner of construction. Machine-made rugs consist of plastic derived fibers being glued onto a strong plastic base which makes them initially very durable, but over time the adhesive degrades and the fibers detach easily from the base. It is said that for rooms with modern designs or active areas with high traffic or children, machine-made rugs with contemporary designs are excellent. On the other hand, there is a common misconception that hand-made oriental rugs are delicate and not durable. Their ornate designs and soft feel often deceive many.

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. Carpet Knots Hand-knotted pile carpets are the most durable in tenure. Tufted carpets with different types of piles or loops are also available but knotted are the best in the category. Usually an Oriental rug quality is judged by the knots per square inch. The more the count, better the quality. Types The most common types of knots used in an oriental carpet are: Persian knot: It is an asymmetrical single knot also called Senneh knot or Farsibaff. Here the thread forms only one loop around one of the two warps. So the pile threads vary in protruding between the adjacent warps. Turkish knot: It is a symmetrical double knot type also called Ghirdes. Here the pile thread forms a loop around two warps. Both ends of the pile thread come out between both warps. Jufti knot: It can be symmetrical or asymmetrical and the difference is that it is formed over four wraps. Tibetan knot: A temporary rod which establishes the length of pile is put in front of the warp. A continuous yarn is looped around two warps and then once around the rod. Once through with the row, the loops are cut to form the knot. Moreover, each knot gives a different texture to the carpet. Knot Density Knot density is an indicator of quality. More the number of knots per square inch, better the quality. KPSI is the density i.e. knots per square

inch. 80 or less KPSI denotes poor quality 120 to 330 is medium to good 330 or more KPSI denotes good to very good quality and more than that are classified as exclusively fine pieces.

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 handknotted 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. Materials 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.

Careers in Carpet industry There are umpteen jobs available in the market for any hard-working and skilled individual. It is said that the career so chosen must be a field of passion. In this competitive environment where everyone wants to reach to the top, it is hard to determine which path to choose. The bottom line is to know what you want to do, being passionate about it and giving in your best to make it a success! Each field has its relevance. No field can be compared to that of another. Some areas that can be chosen by youngsters to pursue their careers in the carpet industry are: ] A Specifier's Rant: The "UN"standardized Carpet Industry I just completed my umpteenth-hundredth carpet specification section and Ive had itespecially when it comes to specifying for public projects. As many of you may know, public projects typically require open competition for projects, including the selection of products that are specified. So, as a response, specifiers are typically tasked to include a minimum of three products in the specifications to ensure competition. So what is the problem? Actually, there are a couple of problemshowever, if one is resolved, the other goes away. The first problem is getting designers to select three acceptable carpets. Since carpet is such a visual item, the specifier should not be left with the job of finding two other carpet selections in addition to the one selected by the designer. Selecting carpet is a mix of color,

pattern, and performance. Carpet color and pattern are characteristics that belong to the designer, but performance characteristics is the area where the specifier livesand is the source of the second problem. The second problem is finding carpeting that has similar performance characteristicsits like asking someone to find three similar marbles in a barrel of marbles. And to compound the problem, there is no standardization in the way carpeting information is presented manufacturers' carpet data use inconsistent terminology and inconsistent units of measurement (if they even bother to provide the units of measurement). For example, I see tufted weight, face weight, and total weight. All have different meanings, but not all are provided in manufacturers literaturemostly, they provide one or maybe two of those characteristics. The Carpet and Rug Institute (CRI), which should be the leader in the industry, doesnt mention any of those in their glossarywhat they provide is finished yarn weightis this a fourth weight characteristic, or is it an alternative for one of the previous three terms? I dont know, because the multitudes of online carpet glossaries vary widely in their definitions, which make it difficult to compare, and almost all dont define more than two of the terms. Surprisingly, ASTM D 5684, Standard Terminology Relating to Pile Floor Coverings, doesnt provide a single definition in regard to weight! Adding to the confusion is the frequent use of proprietary names by manufacturers to describe components of their carpeting, such as fiber and backings. So, how is a specifier (let alone a customer) supposed to compare the construction and performance of carpeting if the use of terminology by manufacturers is all over the map? This specifiers answer: STANDARDIZE!

Other building finishes use standards to either classify products or to provide a minimum product specification. An example of a classification standard is ASTM E 1264, Standard Classification for Acoustical Ceiling Products. An example of a specification standard is ASTM F 1303, Standard Specification for Sheet Vinyl Floor Covering with Backing. Products complying with these standards are categorized based on physical and performance characteristics. Therefore, two products with the same type and grade (vinyl flooring), or type, form, and pattern (acoustical ceilings), may not be equal, but they can be considered comparable; thus narrowing the field of acceptable products to ease the selection process for the designer or specifier, or simplifying the substitution review process. If the carpet industry would just sit down and create a logical method to identify comparable carpet products, then all the specifier needs to do is provide something like the following: Carpet: Style B; Type III; Grade 3A. Which could mean the following: Style B: Tufted, multi-level loop Type III: Woven primary with foam secondary backings Grade 3A: 3 = Total density is greater than 1800 and less than or equal to 2000 oz./cu. yd. A = Critical radiant flux not less than 0.45 W/sq. cm If other characteristics are important, such as fiber material and pile thickness, then those could be added to the specification, along with a basis-of-design product to establish a color and pattern to achieve. Of course, to make such a standard worthwhile and beneficial to design professionals, manufacturers would need to use the system in their product literature. Also, measuring density would need to be standardized through a standard test method.

This may be a specifiers a pipe dream, but if the paint industry can pull it off, so can the carpet industry. It took years, but a system was developed to help categorize an ever-changing paint industry; the system isnt perfect, but its a start. The carpet industry needs to take a lesson from their fellow manufacturers of architectural finishes who have standardized their respective industries and follow suit. CARPET INSPECTION Residential and commercial carpet inspections are required when there are misunderstandings or complaints about carpet performance. An IICRC-certified inspection is required by most carpet mills/manufacturers, and may be requested by anyone who is in the carpet value chain, including the retailer, installation contractor, enduser or consumer. The inspectors job is to collect forensic evidence about flooring problems and express his or her observations and conclusions about that evidence in a clear and concise report suitable for use in a court of law. Questions regarding carpet performance generally fall into one or a combination of the following categories:

Manufacturing Specification Installation Maintenance Misunderstanding of inherent product characteristics

Not only do cleantrust inspectors understand inspection, but they are also required to have training and certification in carpet cleaning, stain and spot removal, repairs and installation. Maintenance

CARPET MAINTENANCE & CARPET CARE TIPS A regular carpet maintenance program extends the life of the original appearance of your carpet. Today's carpet fibers are designed to hide dirt and reflect light and have the ability to resist soiling and stains. However, the lack of apparent soiling does not eliminate the necessity of regular cleaning. CARPET MAINTENANCE For ideal carpet maintenance, you will need to vacuum your heavy traffic areas, such as hallways, stairs, and exterior entryways at least twice a week. Vacuum less heavily used areas weekly. For best results, use a vacuum cleaner with a beater bar or rotating brush and with a strong enough air flow to penetrate to the carpet backing. Carpet with thick loop pile construction, particularly wool and wool blend styles, may be sensitive to brushing or rubbing of the pile surface and may become fuzzy. For these products, and those styles with a combination thick or thin or cable yarn, a suction-only vacuum is recommended for the best carpet maintenance. If that is not available, use or a vacuum with an adjustable brush lifted away from the carpet so it does not agitate the pile. A vacuum with a beater bar or rotating brush can be tested for excessive fuzzing in an inconspicuous location before regular use. Carpet One Floor & Home does not recommend a vacuum brand.There are brands that offer adjustable beater bars or even a feature to turn the beater bar off in some cases. The Carpet and Rug Institute(www.carpet-rug.org) also offers information and ratings of vacuums to provide the best new carpet care. Most dry soil has razor-like edges that abrade carpet fibers, causing light to reflect differently and give carpet a dull appearance. Soil can damage the fibers permanently if allowed to remain in the pile. A regular carpet maintenance program as well as proper carpet cleaning methods will keep your carpet beautiful for a long time.

CARPET CARE & CLEANING TIPS No matter how often you vacuum, your carpet will still need heavy-duty cleaning from time to time. Professional carpet care and cleaning is required to maintain your Carpet One Floor & Home warranty. We would be glad to advise you about which cleaning method is best for your particular carpet. Hot water extraction carpet care, either alone or in combination with cleaning, is required to maintain most warranties.* Some styles, however, must be cleaned in other ways. Be sure to check with your Carpet One Floor & Home retailer for the recommended cleaning method for your particular carpet. A trained carpet care professional should perform this service at least every 18-24 months to refresh the texture and rejuvenate the fibers in your carpet. Have the cleaning professionals come to your home for a visual inspection, and obtain a written agreement before the work is started. You must retain your receipts for proof of maintenance service should a warranty claim arise. When you and your carpet cleaning professional choose a cleaning method, fiber content is the most important concern. Most carpet today is constructed with synthetic fibers such as nylon, polyester, or olefin and may be cleaned with most cleaning methods. Natural fibers such as wool, cotton, silk, and sisal may require specialized care. Use a cleaning method recommended by the carpet manufacturer to maintain their warranty, and if you should have any questions or concerns about your new carpet care, just call your Carpet One Floor & Home retailer.