Here I have discussed about the basic manufacturing process of Knotted and Tufted Carpet

1. BASIC ON
CARPET MANUFACTURING
PROCESS
By
Er. Mahesh Pratap Dubey

2. CARPET
Contents
❑ Introduction
❑ Classification
❑ Productions
❑ Application

3. Introduction
➢ A carpet is a textile floor covering that combines an attractive appearance with
warmth and comfort for standing, walking on. Carpets bring many diverse
benefits to homes and public spaces.
➢ Carpets are comfortable and bring warmth and well-being to the space in which
they are installed. When choosing a high quality carpet, you are assured a flooring
solution encompassing:
✓ Style
✓ Quality
✓ Comfort
✓ Hygiene
✓ Cleaning
✓ Indoor climate
✓ Acoustics
✓ Energy
✓ Safety

4. Definition & Concept
A carpet is a textile floor covering typically consisting of an upper
layer of pile attached to a backing.
The pile was traditionally made from wool, but since the 20th century,
synthetic fibers such as polypropylene, nylon or polyester are often
used, as these fibers are less expensive than wool.
The top layer of the carpet, which is subjected to foot traffic is called the
pile, and it composed of an array of millions of yarn segments, arranged
as short loops or upright tufts.
Today’s carpets come in a huge range of combinations of constructions,
textures, colours and patterns.

5. ➢ A carpet pile is characterised in various ways, for example:
✓ The pile fibres, e.g 100% wool, 100% nylon, 80% wool/20%nylon etc,
✓ Method of manufacture : (a) woven – Ax-minster, Wilton, etc; (b) tufted;
✓ The general pile construction: loop pile or cut-pile, and combinations of these
two types;
✓ Pile texture: eg, frieze, plush and velvet (cut pile types which differ in their levels
of tuft definition);
✓ Pile colour and colour variation (design): plain shade, berber/heather or
patterned;
✓ Pile construction: tuft or loop spacings along and across the carpet, pile mass
density, pile height and pile thickness.
✓ Carpets suitable for heavy, medium and light foot traffic situations

6. CLASSIFICATION OF CARPETS

7. Carpet Manufacturing
❑ As for different types of carpets there are different process.
❑ So, we will discuss only some common terms used in all types of carpet
manufacturing process.
❑ Manufacturing Process of Hand Knotted and Tufted carpet.
General construction terminology
Carpet textures
As well as being manufactured in two distinct ways, ie, tufting and weaving,
carpets are made in a wide range of pile textures. In carpets, the term
‘texture’ refers to the visual and tactile finish of a carpet. The two basic
texture choices are loop pile and cut pile, but within these wide ranges of
textures are possible

8. ➢ Loop pile:
The level loop pile has loops of yarn of uniform length formed in
continuous rows creating an informal look.
➢ Cut pile
The cut pile style results from cutting the tops of all the loops during
tufting, with each loop becoming two tufts.
➢ Cut/loop pile
This is made by combining high cut pile and uncut low loop pile. The cut-
loop (or tip-sheared) texture has a sculptured appearance, created by
cutting some loops while leaving others uncut at the same level.
Loop pile Cut pile Cut/loop pile

9. Hand Knotted Woolen Carpet Manufacturing
Balling of warp yarn
Warping
Beam Mounting
Shedding of warp yarn using gulla and kamana
Knotting
Finishing

10. Balling of warp yarn
➢ Select a hank for balling
➢ Place the selected hank of yarn over the charkhi as shown in the Fig 1
➢ Identify the loose end available from the hank
➢ Draw the identified loose end.
➢ Wrap the yarn around your four fingers for 25-30 warps and form the
ball as shown in Fig 2
Fig 1 Fig 2

11. Warping
➢ Hold two rod of 2” x 4’ of carpet length + 8 ft. extra straight over the ground
and insert to the depth of approx. 6” using iron hammer in a manner that you
can protect your hand holding the rod. Fig 1
➢ Insert another rod of 0.5” x 4’ at a distance of 18” from the first rod as per
step1
➢ Tie the available loose end of the ball with first rod.
➢ Bring the warp thread to the right hand or left hand side of the second rod over
the left or right hand side of the divider rod and take the warp back to the left
or right side of the first rod
➢ Separate each pair by using thread as shown in fig 3 and 4

12. ➢ Isolate each pair of warps on the middle of both rods
➢ Replace the divider by inserting a 2 Ply warp yarn from one side and
make a U shape before tying both loose ends at the starting side.
This helps in making shed in the next operation.
➢ Spread the threads on the both rods throughout the width of the
carpet
➢ Transfer the wrapped warp sheet along with the rods for mounting
this on to the loom.

13. Beam Mounting
➢ Wrapped warp sheet along with the rods are
brought and kept on the other side.(opposite side
of the weaver seat)
➢ The warp sheet along with thin rod is raised and
passed on to the upper beam (from the weaver
sitting side) making an inverted J shape on upper
beam in such a manner that the thin rod sits on to
the row of hooks situated on the beam.
➢ Now the warp sheet is wrapped on to the upper
beam (using Tang) upto the point, where the
remaining length of the warp sheet equals the
distance between the two beams(upper &lower).
➢ Warp sheet is now ready for the next process.

14. Shedding
➢ The divider 2 ply rope used to raised near to the level of upper Beam.
Tie the gulla with warp yarn.
➢ Tighten a 2 ply rope along the length of the Gulla.
➢ Insert an Iron rod in between the shade (parallel to the divider rope, at
a distance 1’ beneath).

15. Knotting & weft yarn preparation
➢ To prepare Woollen yarn ball (Kabli)
Depending upon the plies requirement in the Carpet pile yarn, we take
no. of such woolen yarns to group them and form a package known as
“Kabli”. The wt. of the Kabli varies 200 gm to 400 gm, according to the
requirement.(As shown in fig 3)
Kabli is hanged on the loom and easy unwinding is ensured during
carpet weaving process.
➢ To prepare Cotton Yarn Tharri (twisted)weft
➢ To prepare Cotton yarn Lachhi (untwisted)weft
3

16. Knotting
• In the hand-weaving of carpets, the
weaver weaves up to 15 centimetres
of foundation fabric and then inserts
his first row of knots on the warps.
• The knots of pile yarn are tied in by
the weaver, who brings forward a
back warp-thread level with the next
front thread and knots the pile yarn
around them.
• The knots are pulled tight and the
yarn ends are cut to the length
needed.

17. ➢ After each row or part of a row of
knots is tied, two weft yarns are
inserted through the shed formed
between the front and back halves
of the warp, and through the
reverse shed formed by temporarily
pulling forward the back half of the
warp.
➢ The teeth of a heavy comb or
beater are passed between the
warp ends to beat down the weft
into place and make the knots firm.
Turkish knot
Hand comb used in hand-knotting
Final product
Knotting

18. Finishing
➢ Back finishing of carpets
➢ Brushing, steaming and shearing
➢ Special finishing treatments
✓ Insect-resistant finish
✓ Stain-blocking treatments

19. Hand Tufted Carpet Manufacturing
Stretching of primary backing fabric on Tufting Frame.
Tracing over primary backing fabric for Plain/Design Carpet.
Tufting Activity on Primary Backing Fabric
Carpet backing
Finishing

20. Stretching of primary backing fabric on Tufting Frame
➢ Place the tufting frame of the specified size on the ground.(keeping the
nailed portion upside, as shown in Fig 1)
➢ Spread the primary backing fabric on tufting frame in such a way that it will
cover the whole frame area and over hang at least 5” from all four sides.
➢ Fix the lengthways direction of the fabric on the nails (existing on the
shorter side of the frame) attached to the tufting frame. (as shown in Fig 2)
➢ Stretch the fabric in lengthways direction properly to create appropriate
Tension in the same direction.
➢ The Tufting frame is now ready for next operation.
Fig 1
Fig 2

21. Tracing over primary backing fabric for Plain/Design Carpet
➢ Take the Mug and pour 150 ml of Kerosene oil into it, and
Pour 50 gm Neel or indigo color.
➢ Place the Stenciled Tracing Paper uniformly on the
framed primary backing fabric. The dimensions of the
Stenciled Tracing Paper is same as the dimension of the
Tufted carpet, we are interested in to make.
➢ Apply the viscous solution (Robin blue powder and
Kerosene oil) on the Stenciled Tracing Paper uniformly,
with the help of Cotton Cloth.
➢ This viscous solution will make an impression on the
framed Primary backing fabric.
➢ Stenciled Tracing Paper is removed carefully, so that no
marking other than design will come on the primary
backing fabric.
➢ Now the system is ready for next operation.

22. Tufting Activity on Primary Backing Fabric
➢ Tools
i. Manual Hand Tufting gun.
ii. Woolen (Tufting) Yarn: 2 Ply (60s, 80s etc or as per quality).
iii. Framed Primary fabric with design impression.
iv. Design Map.
v. Bench for sitting.
Tufting Gun

23. PROCEDURE
➢ The tufting frame, along with stenciled Primary
backing fabric, is kept at an angle of approx 10-15
0(from vertical) with the support of side wall of a
room.
➢ Insert the 2 plied woolen yarn from top, into the
nozzle of tufting gun. The selection of the woolen
yarn is done as per the Design Map.
➢ The pile height of the tuft is adjusted by adjusting
the setting of the tufting gun.
➢ Hold the moving handle of tufting gun with right
hand and hold the main handle of the gun with left
hand.

24. • Woolen Yarn is inserted into the Primary backing fabric with the
forward and backward movement of the Tufting gun(using its moving
Handle).
• The tufting is carried out either in Horizontal direction or in Vertical
direction to maintain uniform density of the Tuft with minimum
distortion of the primary backing fabric.
Hand Tufting operation

25. Forming loop pile carpet
Forming cut pile carpet

26. Carpet Backing
The tufted cloth, whether it
is loop pile or cut pile, has a
synthetic latex* coating
applied to the primary
backing, and a secondary
backing material of jute or
another fabric is then
attached. The main
functions of the secondary
backing are to anchor the
tufts (or loops) and to give
the carpet dimensional
stability (Figure ).
Backings for tufted carpets
*Latex: A water emulsion of synthetic rubber,
natural rubber, or other polymer. In carpet, latex is
used for laminating secondary backings to tufted
carpet, back coating carpet and rugs, and for back
coating woven carpets and rugs. Almost all carpet
latex consists of styrene-butadiene synthetic
rubber (SBR)

27. Application
Office
Outhouse
ResidenceHotel
Cinema-Halls AutomobileAircraft
Art-Piece

28. Any ?
Contact @
+91-9453374288
anmpdubey@gmail.com