CARPET PRODUCTION

TECHNOLOGY
WEEK ( 1 & 2 )

Dr. Mohamed abd elgawad

introduction

 Carpet defined as a heavy fabric with tufts or pile used as a

floor covering
 carpet is a textile floor covering typically consisting of an
upper layer of pile attached to a backing.
 A new carpet is an investment that is likely to be with you for
years and so, if possible, it is a good idea to choose your
carpet first and then match other items to match it when
decorating or furnishing a room.
Introduction (Continued)

 Before you select your carpet, you should think about

the color, style and texture that is most suited to your
taste and your life style. The type of fiber and the
quality of the carpet is equally important because the
way it performs on the floor will also be a major
consideration.
SELECTION OF CARPETS.
 Kinds of pile fiber.(Wool, Nylon, Propylene, Others)
 carpet construction method.
 choice of backing.
 color, pattern, and finishes.
 Resilience.
 Surface Construction.
 Aesthetics.
 Carpets are divided into 4 grades

1. Is intended for residential or domestic use

2. Is for normal commercial use
3. Is for such public areas, as lobbies where
face weight is important
4. Is for stairs, offices containing chairs with
casters and institutions.
Functions of Carpet

❑ Acoustical
❑ decoration

❑ Atmosphere

❑ Thermal Insulations

❑ Safety

❑ Comfort

❑ maintenance
 Acoustical
 Carpet absorbs ten times more airborne noise than any
other flooring material.
 reducing sound from walking .
decoration
Carpet provides a marvelous choice of colors, textures
and designs to suite every taste.
Give aesthetic value and decorative sense to any place.
Atmosphere )‫(الشعور العام‬
Carpets enhance the feeling of quality in interior
design.
Important factor in enhancing patient moral
hospitals and in student attitude in schools.
 Thermal insulation
 The pile construction of carpet is a highly
efficient thermal insulator.
 Carpet decreases coldness at foot and ankle
levels and lends a psychological warmth's as
well.
 Safety
Carpet ability to cushions falls and prevent
serious injuries.
Comfort
Absorbs shocks and distributes loads.
Maintenance
Protects hard floors from degradation and increases
its lifetime
Disadvantages of carpets.
 Surfaces holds dirt, so carpet cleaning is essential.
 They are cut by sharp edges and can be burnt by
cigarette butts.
 They can be attacked by moths and other insects.
 Plain carpets show stains, which can be difficult to
remove.
 The initial cost is high.
The Factors That Determine Carpet Quality

 In practice, virtually all carpets, irrespective of style

or type, share the same basic construction.

 In other words, there is a pile or surface yarn which

is fixed to a backing material in some way so how
the carpet i.e., Axminster, Wilton or tufted is made
is not necessarily an indication of quality.
The Factors That Determine Carpet Quality (Continued)

Factors affecting carpet performance (quality)

 The pile weight

 tuft or pile density (surface pile density) -

 pile height

 pile material ( fibre or blend of fibres from which

it is made. )
 No. of twist for pile yarn.
The Factors That Determine Carpet Quality (Continued)

 Tuft density relates to the numbers of tufts per square meter of

a carpets. it is governed by the number of tufts across the
width multiplied by the number of tufts in the length .
 The denser the carpet, the longer the carpet will look new. A
good way to check carpet density is to fold the back of the
carpet onto itself, which allows you to see how tightly packed
the yarns are at the fold. If you can see a lot of the backing,
the carpet may not be a good buy
The Factors That Determine Carpet Quality (Continued)

 Carpet of higher tufts density – that is more tufts per

square meter- will perform best
 The weight of the pile and density of the tufts are
some times considered to be the same thing. But they
are not. Surface pile weight is a measurement of the
amount of yarns per square meter of a carpet – it is
pile height that makes the difference to weight .
The Factors That Determine Carpet Quality (Continued)

 The illustration below explains why surface pile density is so

important.

 The top one has a long

pile that will distort and flatten easily. Initially, it may feel soft
and luxurious but will lose its appearance very quickly.
 The lower one has a denser, shorter pile, which means that it will
resist flattening and look better for longer than the one above.
 In practice, the closer the pile is packed together, the longer the
carpet will last because it will resist abrasion better.
The Factors That Determine Carpet Quality (Continued)

For example , if the pile height

of one carpet is 2 cm and
Another is 1 cm and the
the yarn and the pile
weight are identical ,
then the density of the
second carpet is twice that
of the first .
The Factors That Determine Carpet Quality

Carpet construction also includes

the yarn and how it is constructed.
Yarn twist is important in determining
quality carpet. Yarn twist affects a
carpet’s appearance, durability, and
Resistance to matting. If the yarn is
tightly twisted and heat set, the carpet
resists matting and is more durable
than the loosely twisted yarn .
TYPES OF CARPET
 Today’s carpet market is dominated by 2 main varieties:

Loop Pile Carpet Cut Pile Carpet

CARPET STYLES AND TEXTURES
❖ Level Loop Pile
In this type of carpet all tufts are produced in loops
and left uncut. All loops are the same height hence
the term “level loop”.

❖ Multi-Level Loop
A “sculptured” effect can be created in a loop pile
carpet by using varying pile heights.
❖Cut and Loop
As the name implies, it is possible to produce carpet
containing both cut and uncut tufts.

❖ Velvet or Velour
Relatively short pile, which is often fairly dense. The tufts have a
limited degree of “twist” incorporated during the spinning
process. This allows the tufts to “burst” open and create the
“velvety” appearance.
❖ Twist Pile
The yarns used will have a higher degree of twist than the
velvet. As a result the tufts retain a more individual appearance.

❖ Frieze
The yarns used will be produced by folding two or more
individual yarns together. If each component yarn has a different
degree of twist, the resultant yarn will not stand upright but will
take on an irregular or random appearance.
 Saxony
The tufts will be fairly tightly twisted and “heat set” to retain
that configuration. The tuft length will be around 8-12mm (above
the backing). The heat setting allows the tufts to remain well
defined since the amount of “burst” will be restricted, creating a
longer version of the “twist pile.

Plush
Similar to a “Saxony” but without the same degree of heat
setting. The tufts will burst open at the tip creating a longer
version of the “velvet” or “velour”.
 Shag Pile
Tufts can vary from around 25-50mm in length. The extra long
pile will considerably increase the cost of the carpet unless
compensated by spacing them out into a low-density construction.
Most “shag” pile carpets are unsuitable for heavy traffic areas.
Classification of carpets
carpets

Hand made Mechanical

Flat woven tufted woven Non-woven

(kilim)

face to bonded
knotted face

Needle
wilton punch
tufted

axminster