Carpet manufacturing is a complex process involving fiber selection, yarn formation, backing construction, dyeing, printing, coating and finishing. Major carpet fibers include polypropylene and nylon. There are various carpet types including woven, tufted, and non-woven. Key manufacturing steps are tufting the carpet, dyeing the yarn or carpet, and finishing processes like shearing and antimicrobial treatments. India is a major global producer and exporter of handmade carpets.

2. INTRODUCTION
 Carpets are the textile floor coverings used in household as well as commercial
applications.
 Manufacturing of carpet is a long process including selection of fibers, yarn formation,
backing construction, dyeing, printing, coating, finishing etc.

3. Benefits of carpet
Carpet provides thermal resistance, it retains warm air longer and make
place comfortable to sit.
Carpet can add beauty and style to the room.
Carpet softens slips and falls.
It can reduce noise by absorbing noise.

4. Major fibers for carpets
Commercial carpets are made
from BCF while residential carpets
consist of staple fibre
Fibres used in carpets need
certain properties like good
abrasion resistance,resistance to
soiling, ease of cleaning and
reduced static build-up.
Polypropylene meets most of
theses characteristics and hence
its use in carpets is increasing.

5. TYPES OF CARPETS
CARPETS
WOVEN
• WILTON
• AXMINSTER
• ORIENTAL
NON WOVEN
• TUFTED
• BERBER
• BONDED (3 types)
• KNITTED

6. Finishing the carpet
Dyeing the tufted carpet
Tufting the carpet
Dyeing the yarn
Preparing the yarn
Fibre Dyeing
Carpet manufacturing

9. Tufting the carpet
Tufting is the process of creating textiles, especially carpet.

11. Carpet Dyeing
• Fiber melts stage. (e.g. Polypropylene)
• Loose fiber stage. (e.g. large orders)
• Yarn stage (e.g. patterned woven, patterned tufted)
• Piece (e.g. exhaust dyeing)
Coloration of carpets can
take place at following stages:

12. Solution DyedCarpet
 Solution dyeing is a yarn coloration process in which pigment is added to the
polymer melt before the fiber is extruded into yarn.
 The color, therefore, is an inherent part of the yarn itself.
 Solution-dyed fibers have outstanding color fastness.
 Some are solution-dyed for interior use.
 Solution-dyed nylon continues to increase in use.
 Olefin yarns are almost always solution-dyed.
 Solution dyed yarn is highly resistant to color loss through fading from
sunlight, ozone, or harsh cleaning agents and bleach.
 The solution dyeing process is, in addition, environmentally friendly and
efficient, using little water or energy.

13. After dyeing and baling, the fibres is ready to go to the yarn mill for spinning into yarn
the fiber rinsed and then centrifuged to remove excess water.
The kettle is drained
The dyeing is continued until the dyestuff has been completely transferred or exhausted from the bath
onto the fibres.
bulk staple fibres is placed in a large kettle and a prepared dye liquor is forced through the fibres.
Stock Dyeing
 Stock dyeing is the application of color to staple fibers before conversion into spun yarn
 This method of dyeing is use for dyeing of nylon, wool, acrylic and polyester staple fibre.

14. • Carpet yarns are wound onto a skein or put as a
cone into a kind of dye beck.
Hang,Skein or Package
Dyeing
• Process whereby different colors are “printed”
along the length of the yarn before it is
manufactured into carpet.
Space Dyeing
Yarn Dyeing

15. Yarn Dyeing Types

16. Space Dyeing
 Space dyeing is used mainly for wool carpets.
 It consists of sectional printing or dyeing of yarn in various stages of processing,
with various color shades in different intervals and lengths.
 In space dyeing it is scarcely possible to differentiate between dyeing and printing.
 Space dyeing provides an opportunity to create interesting patterns.
 Space dyed carpet is a yarn dyeing process in which different colors are applied
along a length of yarn at intervals.
 Space dyeing, primarily for nylon BCF.
 The three most frequently used techniques are knit-de-knit, warp-sheet printing,
and multicolour skein dyeing.

17. Knit-de-knit Printing
Dyeing & Printing With this technique,
a circular knitting machine forms the yarn into a
tube or sock that is printed on both sides, usually
in diagonal and horizontal stripes
Steaming
Washing Extracting
Drying
De-knitted or unravelled
Wound onto cones.
Warp-sheet Printing –
Dyeing & Printing With this method, a sheet of
yarn is supplied from a standard tufting-type creel. A computer
controlled printer applies a color in various lengths along the
yarn axis.
Steaming
Washing
Drying
wound back onto cones
Methods Of Space Dyeing

18. The carpet is placed in a large vat filled with dyes, chemicals, and water usually in rope form.
 It turns constantly on a reel inside the beck - at an ideal rate of one revolution per minute - so that
dye may be applied evenly.
The liquids in the beck are heated and heat is maintained until the dye cycle ends (about 30
minutes).
The movement process provides maximum colour uniformity, or “level dyeing” . Rinsing and drying
follow.
Beck dyeing generally is used for solid colours.
Beck dyeing is an excellent technique for dyeing carpet pieces or rolls.
Beck Dyeing Carpet

19. Continuous dyeing Carpet
There are numerous techniques and variations in the
continuous dyeing process, but most continuous dye
ranges include the dye process and the finishing
process.
Continuous dyeing carpet method is used for solid-
color cut-pile carpet.
Continuous dyeing is one of the fastest, most cost-
effective means of color application.
The general process for continuous dyeing:
1. Staging, or Preparation: Rolls of undyed goods are
sewn end-to-end to give sample linear footage to ensure
a continuous carpet production line through the very large
dye range.
2. Pre-Conditioning: Wets the carpet with water or
wetting chemicals.
3. Dye Application: Dye liquors are applied by single
applicators for solid colour effect or by multiple applicators
for multicoloration.
4. Steaming: Provides the energy necessary to exhaust
the dye liquor into the fiber.
5. Washing: Removes all residual dyestuffs and
chemicals.
6. Drying: Dries the carpet prior to applying the back
coating and secondary backing.

20.  The majority of the continuous dyed carpet equipment used in the world today is manufactured by two companies in Gemany, Kusters and
Fleissner.
 This type of continuous dyeing method is favoured over beck dyeing due to the fact that costs are lower for utilities, labor, and raw
materials.
 The reason for this is that beck dyeing requires more water, about 6 times more water as compared to a continuous dyeing line.
 Kusters established the first continuous dyeing range for carpets in 1966.
 Continuous dyeing was the basis for an increasing growth of the carpet industry due to higher productivity and cost reduction of
up to 75%.
Kusters continuous dye-range

21. Kusters continuous dye-range

22. Kusters continuous dye-range

23. CARPET PRINTING
 The initial development of the printing of carpet in the UK after the introduction of tufted carpet production, which followed the in the USA from
the early 1950s on wards.
 Printed carpet is available in a wide variety of patterns at a much lower cost.
Methods of carpet printing
Direct
printing
Discharge
printing
Resist printing
Pigment
printing

24. Chromojet Direct Printing

25. PRINTINGMACHINES
 Nowadays,printing industry develops rapidly and new technology adds new equipments and systems on this printing
machines.
 Here are the most commonly used carpet printing machines in textile industry ;
-flat-screen printing machine
-rotary-screen printing machine
-spray and jet printing machines

26. Iris Graphics
STORK
Toxot Imaje
Jemtex
STORK
Epson
Konica
Xaar
Spectra
Hewlet Packard
Canon
Lexmark
Ink-jet systems
Continuous flow
Drop-on-demand (DOD)
Binary
deflection
Multiple
deflection
Mechanical
Piezo - activated
Thermic
"Bubble Jet"
Ink-jet systems

27. Digital printers withRubber Belt, Feeder, Winder

28.  Carpet finishing may be carried out at the end of the carpet manufacturing process or
along with manufacturing process.
 Its aim is to improve the carpet performance and give a better quality. Different finishing
methods are:
1) Dry Finishing Processes- brushing, shearing, singeing etc.
2) Wet Finishing Processes- antimicrobial finish, antistatic finish, FR finish etc.
The carpet finish should have:
1) Simple application.
2) No effect on coloration.
3) High abrasion resistance.
4) Temperature resistance.
5) Good all-round fastness.
Carpet finishing

29.  An antimicrobial finishing destroy or prevent the growth of micro-organisms.
 Antimicrobial agents may be applied on the carpet fibers, in the latex or adhesive holding the fibers, or on the carpet backing.
 Antimicrobial agents can be divided into two groups;
1. membrane-active compounds
2. electrophilic agents.
 Membrane-active compounds include alcohols, quaternary ammonium compounds, acids, phenols, salicylanilides etc.
 Electrophilic compounds react with nucleophilic components of the cell and inhibit the vital activities in the cell. These include aldehydes,
activated halogen compounds, isothiazolines, mercury compounds etc.
antimicrobial finishing

30. a person walking on an insulating carpet should not become highly electrically charged. Accumulated electric charges may cause an electric shock when
discharged to earth.
Antistatic finish can be imparted by following ways:
 Slope-padding/ spray application of antistatic agents.
 Incorporating the steel fibers into carpet construction.
 Addition of electrically conductive products to carpet back-coating.
 Use of antistatic pile fibers in form of synthetic fibers with hollow spaces and electrically conductive additives.
 Use of electrically conductive adhesives to facilitate the discharge of static electricity.
Antistatic finish

31.  Various flame retardants are available in market which provides durable flame retardancy.
 Most widely used is the THPC (Tetrakis Hydroxy methyl Phosphonium Chloride) – APO (Aziridinyl Phosphine Oxide)
system.
 Fluorinated inorganic-organic finishing materials prepared by sol-gel process using polymethacrylic
acid (PMMA), tetraethoxysilane (TEOS) and perfluoroalkyltriethoxysilane are applied to nylon carpets to
improve water repellency, compressibility, surface friction, soil release, stain resistance and flame retardancy
simultaneously.
Flame Retardant finish

32.  Lanasan NCF i.e. Nano Carpet Finish is a Nano tech. product
 to improve the manufacturing properties of wool carpets
 developed by Clariant
 It consists of optimally sized Nano particles
 which are applied to wool yarn during dyeing adhere to the surface of the individual fibres.
 This increases fibre friction which in turn lead to stronger yarn and more stable pile which improves abrasion resistance.
Nano Carpet Finish

33. CARPET SHEARING WITH XETMA VOLLENWEIDER

34.  ‡special shearing unit mounting with integrated dust suction
 ‡optimum design of shearing table in idle or roller type version
 traverse movement of shearing cylinder
 automatic shearing start-up process to avoid stopping marks
 ‡automatic lubrication of shearing unit for maximum serviceable life
 ‡automatic lifting of shearing unit during seam passagewith soft touch down

35. FINISHING OF CARPET PILE

36.  cARPET PILE CLEANING
• cleaning of all kinds of woven and tufted carpets
• removal of loose fiber material from the carpet pile
• efficient cleaning due to:
 2 brushing units
 2 scratching unit
 robust design for long machine service life, especially with large working widths
 HIGH PERFORMANCE DRIVE SYSTEM
• very powerful, machine integrated dust extraction system
• low operating costs due to low maintenance drives and ultra-low energy consumption
 USER-FRIENDLY OPERATION
• menu-driven colour touch screen for all process parameters
• straightforward operating software and simple handling of all power units

37.  Application
 LaminationRanges
 TuftedCarpetBackCoating
 CoatingRangesforBathroomCarpet
 CoatingRangeforArtificalGrass
 CarpetDryers
 NeedleFelt(nonwoven)Coating
 BINARYSTREAMTECHNOLOGY
 Thatcontrolstheheatsettingsbetweentopandbottomseparately
 Homogenousheattransferis accomplishedintheleft,middleandrighthandsideof thecarpet
 Perfectmoisturecontrolof theexhaustair
 Individualwidthcontrolof eachstentercompartment
 Enormousenergysavingcomparedto theoldtechnology

38. SPECIAL FINISHING LINES FOR Particular CARPETS
 There are as many demands on the manufacturers of finishing technologies as there are types of door covering and materials used.
 xetma Vollenweider therefore offers individual finishing lines optimised for both performance and quality.

39.  The presence of woollen carpets in India was recorded as early as 500 BC
 Today, India is the world’s largest producer and exporter of hand-made carpets, both in terms of value and
volume.
 In fact, around 90 per cent of Indian-manufactured carpets are exported.
 In 2013-14, the total value of hand-made carpet exports was US$ 1,037 million.
 Exports have grown from US$ 737 million in 2009-10 to US$ 1,037 million in 2013-14, at an average rate of 8.9
per cent.
 Indian hand-made carpets are exported to over 100 nations.
 There are about 2,500 carpet manufacturers in India.