With the knowledge of knowing how your carpet is made, you can understand the product's materials, their performances, installation, durability, and how they need to be cared for. At Technique Flooring & Restoration we don’t want to just sell you carpets, we want to inform you so you can become the best shopper.
Fiber is the basic material of which carpet is made. Over 90% of all the carpet made today is made from synthetic fiber. The rest is natural fiber usually wool. Synthetic fibers are made up of 3 materials:
All three of these options are created by similar chemical processes using oil and natural gas.
Almost 75% of carpet today is made of the best overall. It is widely popular due to its ability to fade less over time and be heat resistant, along with soil and stain-resistant. Which can be a good option due to the Central Texas environment.
Gaining in popularity is the fiber polypropylene. This fiber represents more than 35% of the total fibers used in the carpet industry. Its benefits include being naturally resistant to stains, fading, and moisture. Polypropylene can be seen typically in loop pile carpet constructions.
Not only used for clothing polyester is also used primarily for its bulkiness, color clarity, and its stain and fade resistance. With the newest technologies today, polyester has strived in its popularity.
Another type of carpet fiber which is commonly used in carpet construction is staple fiber, made from wool and is all natural. Since it is a natural fiber, it ranges in color from off-white to black, including several earth tones in between. Although wool doesn’t perform as well as the other fibers, it cleans well and holds its longevity. Being the most expensive fiber – wool represents less than 1% of the U.S. carpet market.
This is a process of weaving the fibers into a primary backing material made of woven polypropylene. Its main value is to provide a base cloth to hold the yarn in place while the tufting happens. Tufting is done with a tufting machine that has up to 2,000 needles working together to pull the yarn through the primary backing material. As the needles penetrate the backing, a small hook, called a looper, grabs the yarn and holds it in place. This process results in what is called loop pile construction. Loop pile products hold their appearance exceptionally well because there are no exposed yarn tips.
Carpet can be taken through one of two dyeing processes. The first method of dyeing is called yarn dyeing or pre-dyeing. This is when color is applied to the yarn prior to tufting. The second method involves applying color to the yarn after the carpet has been tufted. This method is called carpet dyeing. Carpet dyeing can be done through three different techniques.
-The first technique, often referred to as Beck or batch dyeing, involves stitching the end of the carpet together and then running the tufted carpet loop through large vats of dye and water for several hours. This process is ideal for smaller production runs and heavier face weight products.
-Continuous dyeing is a similar process but 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 can be used to create multicolor or patterned effects.
-Screen printing is another common method of carpet coloring and color is applied through silk screens. The major benefit of carpet dyeing after the tufting process is greater color flexibility and a lower cost.
This is typically a single production line that completes the final stage of the carpet construction. In the finishing process, a coating of latex is applied to both the tufted, dyed carpet’s primary backing, and is also added to a secondary backing. The secondary backing is typically made of a woven synthetic polypropylene material. The two parts are squeezed together in a large heated press, where they are held firmly to preserve their shape. Shearing happens during this time and all the loose ends and projecting fibers are removed. This also helps achieve the yarn’s tip definition. Finally, each carpet is carefully inspected for color uniformity and other manufacturing defects before it is rolled, wrapped, and shipped.