Carpet manufacturing steps
Machine carpet is a term that includes different types of flooring depending on the type of yarn used and the type of weaving technology.
Sometimes fantasy rugs or tufted rugs may also be classified as machine-made rugs.
In this article, we will explain the technology of machine-made carpets based on the texture weaving technology.
In RubyRug, the production chain consists of four main stages, which are: spinning, dyeing, weaving and finishing.
First, the weaving process is done by carpet weaving machine. At the end, after shearing and packing, it is sent to the destination markets for sale in the carpet finishing unit. In the following, along with the pictures of Ruby carpet factory, you will see how to produce machine-made carpets by observing the production stages of machine-made carpets from the beginning to the end.
weaving machine carpet stage
The most important step in the chain of machine carpet production stages is weaving. At this stage, the carpet is woven using different technologies. In general, the carpet weaving system is the same as the fabric weave, except that it is woven with two wrap systems.
In fact, in a knitting machine, two carpets are woven at the same time, one is called the top carpet and the other is called the bottom carpet.
This weaving system is also known as face to face weaving. In fact, the two fabrics are woven in parallel, and the sleeping yarns are placed between the two surfaces. It is then cut in half by a reciprocating blade and the two carpets up and down are separated. Of course, the system described actually shows the general process of carpet weaving, but the different machines developed by carpet weaving companies make different possibilities in carpet weaving available to manufacturers.
Carpet weaving machines are mainly produced by two well-known companies Wendville (Belgium) or Schoenherr (Germany) and are available in different models. These companies can produce carpets with cut pile or loop pile or with three weaving systems (rapier). Each of these features is designed in different models of these companies. Some of the models manufactured by Wendville include CRX, CPX, HRX, UCL, HCPX, and CRP.
Cutting carpets in the machine carpet weaving unit
Side view of a carpet weaving machine
Completing stage of machine carpet
After leaving the knitting machine, the machine-made carpet has small defects that will need improving, and in order to increase the gloss and appearance of the carpet, as well as to improve its durability, it must go through the steps of finishing. The carpets are sewn together first, and in the next step, the dust and lint from the weaving stage are removed.
In the next stage of the production of machine-made carpets, which is very important, the sleeping surface of the carpet is covered with special blades and its sleeping surface becomes uniform and shiny. This step, called shearing, will greatly affect the final quality of the carpet. In the next step, it is the turn of Aharzani. At this stage, the back of the carpet surface is impregnated with special resins and adhesives to strengthen the woven knots in place. In the last stage of completing the machine carpet, longitudinal and transverse sections of the carpet, as well as edge embroidery and Rishezani are performed.
Steps to complete the machine carpet
Technical parameters affecting the quality of machine-made carpets
Apart from general factors such as knitting machine model, weaving technology, type of yarn used for weaving, warp and weft density and general machine settings, there are three other important technical factors that can affect the final quality of machine-made carpet:
- Proportion and uniformity of the physical characteristics of the sleeping thread: The quality and uniformity of the physical characteristics of the used sleeping thread are very important. Unevenness in the physical properties of the yarn (such as elongation, shrinkage, or shrinkage percentage) can cause longitudinal streaks on the carpet surface.
- The quality of the cutting blade: The cutting edge of the carpet is also one of the factors that can affect the final quality. These blades should be of very good quality and should be replaced in a timely manner, otherwise they will cause a problem of sleep deprivation.
- Shearing stage: uniform the sleeping surface of the carpet, which is called shearing, has a great effect on the final quality of the carpet.