How Carpet Is Made: Springfield, MO.
We have been decorating our homes with carpet since nomadic Middle Eastern tribes laid it down in their huts 2,500 years ago. Today, more than a billion square feet of carpeting is produced in the United States each year; about 70 percent of that comes from a single town, Dalton, Ga.
Carpet may be somewhat easy to overlook, but if you get down close to the stuff, you'll find not all carpet is alike.You can learn a lot about carpet just by running your fingers over it. You'll find out whether the pile, the exposed top part of carpet we usually refer to as "carpet", is composed of individual strands (cut pile) or closed loops (tufted). You'll also be able to determine the density, or face weight, of the pile. You may also find that what you thought was a monochromatic (a single color) carpet is actually the result of an optical illusion where several different dyes combine to create what looks like one color. Most carpet made today is tufted, or woven into closed loops. This method was developed in Dalton, Ga. the carpet capital of the world near the turn of the last century.
So here's how it’s made: First the yarn is spun, usually from synthetic fibers. Then needles push the carpet fibers through the underside of a piece of fabric called the carpet backing. A hook called a looper holds the fibers in place as the needle goes back down into the backing, forming the loop. It sounds a bit tedious, and it must have been before the advent of automated tufting machines. Today, these machines measure about 12 feet wide, with between 800 to 1,200 needles working to create carpet quickly and steadily.
If the carpet is supposed to be tufted, then the actual creation process ends here. If cut pile carpet is being manufactured, however, then the tufted carpet goes through an additional step where the loopers holding the individual pile strands are pulled over sharp knives. This cuts the loops into the individual strands that make up a cut pile carpet.
The coloring process may take place at different stages in production, depending on the desired visual effect. As we mentioned earlier, some carpet is put into vats of water after production and boiled while dyes are mixed into the container. This is known as the Beck process. Another method, continuous dyeing, rolls and sprays dyes onto finished carpet. Still another, pre-dyeing, takes place before the carpet is processed. The actual yarn that will be used in the tufting process is dyed beforehand, which allows for uniform color. Take a look at the video for a more complete and detailed look at how carpet is made.
To see how carpet is cleaned, Call Ultra Carpet Care of Springfield, MO. to schedule your appointment and we’ll show you right in the comfort of your own home. Call Today (417) 459-1971