carpet industry

7/30/2019 Carpet Industry

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CARPET INDUSTRY

Establishment

In late 19th century, a carpet trading concern was established by a noble and versatile business merchant

named Sheikh Din Muhammad.

Later his all four sons carried forward and expanded carpets business and enhanced its prestige andgoodwill by dint of relentless working, pragmatic planning and good business governance.

Soon after the emergence of Pakistan, one of the four brothers, Sheikh Ahmed Hassan founded Lahore

Carpet Manufacturing Co. in 1949. This new company carried on the tradition of excellence and firmly

established its reputation as producer of high quality carpets with an identity of their own. Later the family

business was converted into a corporate business. Which is being now run by familys third generat ion with

fourth one is on its doorsteps. During its 58-year journey, the company crossed many milestones in its

unrelenting efforts in achieving excellence in quality of products and processes.

Differential Characteristics

We own all departments of production & finishing under one roof except weaving. Having manufacturing experience of more than 55 years. We are introducing "Modern Management Techniques" of integrated approach to achieve the

maximum output in minimum time.

Own personal "Raw Material Resources" We have "Walk In Management" so in case of any problem directors and managers have direct

access to the work at any time.

Innovative Manner

We have R&D department, which is continuously working on developing new collection design,processes, material and introducing new trends according to the requirements and establishing the

existing ones.

As the natural colors attracts attention and fascinate more than the artificial colors so we have ourown vegetable dying unit, tremendously working for natural colors.

Vision Statement

"To become a leading manufacturer of the world by creating attractive and unique designs adopting

innovative techniques and endeavoring to produce for carpet loving people".

Mission Statement

"To be known as trend setters in the carpet industry catering to the customers demand by reading the

wishes in their eyes and turning them into reality before they give their thoughts as expression".

Core Values

The first and the foremost thing for us is our commitment. If we commit, then we do it with righteousand virtuous manner.

We are keen to develop strong relationship to endorse healthy environment for business.


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Latif Enterprises Produce the Best Quality hand made Carpets fromPakistan at the most Competitive Prices.

One of the largest Companies of Pakistan dealing in Hand Made Carpet

was established 35 years ago. The company is well known all over the

world for making of hand-knotted carpets in wide variety of designs

and colors. With its vertical and horizontal integration the company has

all facilities available for making of best quality hand made carpets.

Manufacturing Process

Hand-made carpets are technically very different from machine-made

carpets. As it is quite relevant from their names, hand-made carpets

are woven by hands while machine-made carpets undergo treatments

by various machines

Process of hand-made carpets Process of machine-made carpets

HAND MADE CARPETS

Hand-made carpets are traditionally more expensive than those made

by machines. Though there are several carpet-making methods,

including braiding, hand tying (or hand knotting), hooking, shearing

and tufting, the most common of these are braiding and hand

knotting.Braided carpets are done by connecting or tying strips of fabrics

together. Hand tying or hand-knotting are usually done on rugs.

Countries that are known to produce beautifully crafted hand-knotted

rugs include Spain, Portugal, India, Pakistan, Turkey, Afghanistan and

Japan (among others). Hand-knotted rugs are descendants of Oriental
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Rugs and can be made in any shape, size, coloured or design.

Process

The process that creates a hand-made/hand-knotted carpet can be

explained as under:

Wool sorting & Washing

Wool is either imported or is bought from nearby markets and is

carefully sorted to pick out unwanted particles. Wool often

carries dust, grease which is removed by washing it thoroughly

and is then sun dried for two-three days.The Tibetan wool has a strong good fibre length is imported in

scoured form, good lustre and a high resilient value. The New

Zealand wool is of 36 micron, 100 mm barb length and is

identified as type 128. British wool meeting regulatory standards

have also started being available in the market.

Carding

The carding process allows the fibre stand to flow smoothly

when spinning. This is also the stage for blending different wools

and to ascertain the ratio of different origins. Traditionally,

carding was performed by hand and machine carding was

introduced when the industry grew. However hand carded

product is still available if a customer so desires.

Spinning

The carded wool is spun into yarn by using a charkha or aspinning wheel. The thickness of the yarn depends on the

quality of the carpet and generally a 3 ply yarn is used.

Dyeing


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The traditional pot dyeing method has been largely replaced by

machine dyeing in closed Chambers. Dyes containing harmful

substances such as AZO are banned and dye-stuffs

from renowned international manufacturers are used. These

dyes have a high degree of fastness. Depending on the weather,

the dyed yarn has to be dried in the sunlight for one to three

days. Pot dyeing and vegetable (natural) dyeing are still being

used by some manufacturers.

Carpet Knotting

Knotting is an art. Weavers who weave on a regular basis have a

very good speed in knotting. They tend to develop this speedover a span of time. One or more weavers work on a loom

depending on the size of the carpet. Each weaver makes

individual knots row after row. The designs are chartered out on

a graph and a map reader or another weaver instructs the

graphic designs to the ones knotting the carpet. The dyed yarn is

made into balls and scissors, iron rod, levers, comb beaters are

used as tools.

Trimming

The finished carpet is taken off from the loom and the designs &

patterns are trimmed by scissors.

Washing and Drying

The trimmed carpet is washed with the fresh water & chemicals.The washed carpet is dried in the sunlight up to four or five

days.

Final Touches


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The dried carpets are given final touches by re-trimming and

stretching, where ever necessary. The purpose is to bring the

fabric woven in level at the surface.

Packing

All washed carpets are rolled and wrapped in polythene sheet

and is sealed at each end. Again, it is wrapped in Hessian cloth

and sewn. Generally, around 14m2 are packed in each bale.

Payment

Export proceeds must be received through an irrevocable letter of

credit (L/C) or advance payment

Machine-made carpets are tufted, woven, knitted, flocked or needle-

punched. Most commonly tufting is used for machine-made carpets.

Tufted carpets are made on machines where the yarn is stitched

through a pre-constructed backing to form a loop or a tuft. To hold the

loops in place, the back side of the carpet is coated with latex.

Tufting is the most inexpensive and fastest ways to manufacture a rug.

Weavers can also control the tuft size making it possible to create

carpets with varying patterns or surface textures.

There are three kinds of woven carpets: Velvet, Wilton and Axminster.

Velvet is the least complicated of construction methods. Velvet carpets

usually come in one solid coloured and a tweed effect may be noticed.

Wilton carpets are more intricate. These are manufactured by using a

Jacquard loom which can hold up to six different coloured of yarns.

The Axminster method of weaving carpets produces the most

elaborate designs with a wide variety of coloured.

Knitted carpets are faster to make. In knitting, several sets of needles

create loops and these are stitched together before the backing is

applied. Knitted carpets come in solid or tweed and the pile may be of


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the same size or of varying heights.

Flocked carpets are similar to Velvet carpets in appearance. They

have a dense cut pile of short fibres that are imbedded into an

adhesive-coated backing.

Needle-punching is similar to hand-hooking. Formerly used for

indoor-outdoor carpets, this process is now being used for carpets that

are only meant to be placed indoors as well. In needle-punching, fibres

are locked into a packing by using hooked needles, which are further

compressed.

The Manufacturing Process

The process of manufacturing tufted carpets can be explained in the

following steps:

Step 1: Preparing the yarn

First, the synthetic yarns arrive at the carpet manufacturer either in

staple fibre form or in bulk continuous filament form

The staple fibres, which are an average of 7 inches (18 cm) long are

generally loose and are individual strands that arrive in bales. Several

bales are blended together into one batch in a hopper.

Then, these strands are lubricated and are spun into long, looseropes called slivers by a carding machine. The slivers are then pulled,

straightened, and spun into single yarn that is wound onto spools.

Both the single-ply staple fibres (now spun into filament) and the

bulk continuous filament is then twisted together to form thicker two-

ply yarn suitable for tufting.

The yarns are then steamed to bulk them, and then heated to 270-

280F (132-138C). This heat setting causes the yarn to maintain its

shape by fixing its twist. After cooling, these yarns are wound ontotubes and transported to the tufting machines.

Step 2: Dyeing the yarn

Generally, most carpets are dyed after tufting yet sometimes the


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yarns are dyed first. The methods include putting 500-1,000 pounds

(227-455 kg) of fibre into pressurized vats through which treated dyes

are circulated, or passing the fibre continuously through the bath, or

passing skeins of yarn through the vat of dye.

The yarn can also be put on forms, and the heated dyes can then be

forced under pressure from inside the forms to coloured the yarn.

Another method passes the yarn through printing rollers, while yet

another involves knitting the yarn onto a form that is then printed with

dyes before the yarn is unraveled. All yarn that has been dyed is then

steamed, washed, and dried.

Step3: Tufting the carpet

At this stage, the yarn is put on a creel (a bar with skewers) behind

the tufting machine and then fed into a nylon tube that leads to the

tufting needle.

The needle pierces the primary backing and pushes the yarn down

into a loop. Photoelectric sensors control how deeply the needles

plunge into the backing, so the height of the loops can be controlled.

A looper, or flat hook, seizes and releases the loop of yarn while the

needle pulls back up; the backing is shifted forward and the needleonce more pierces the backing further on.

Inorder to make a cut pile, a looper facing the opposite direction is

fitted with a knife that acts like a pair of scissors, snipping the loop.

This process is carried out by several hundred needles (up to 1,200

across the 12 foot [3.7 ml width), and several hundred rows of stitches

are carried out per minute. Thus, one tufting machine can produce

several hundred square yards of carpets per day.

Step 4: Dyeing the tufted carpet Solid coloured carpeting: For this carpet of several standard roll

lengths is sewn together to make a continuous roll, which is then fed

into a vat. The vat is filled with water, which is first heated before dyes

and chemicals are mixed in. The mixture is then slowly brought to a

boil and cooked for four hours approx.


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Another method of making solid coloured carpet is to sew several

rows together to make one continuous roll, which is then fed under

rods that bleed the coloured into the pile. After dyeing, the carpet is

then steamed to fix the coloured, excess coloured is washed off, and

the carpet is dried and put on a roll.

Printed Carpets: Inorder to make printed carpet of various designs,

white carpet passes under screens in which holes in the desired

pattern have been cut. The desired coloured is squeezed through the

holes in the screen, and the carpet is advanced 36 inches (91 cm) to a

different screen that applies a new coloured in a different design

through the screen. Up to eight coloureds can be applied with this

method.

Another method of dyeing printed carpet is to pass it under

embossed cylinders that have raised portions in a design that press

colour into the carpet. Each cylinder provides a different design for a

different coloured. After dyeing, the printed carpet is steamed, excess

dyes are washed off, and the carpet is then dried and put onto rolls to

go to the finishing department.

Step 5: Finishing the carpet

The ends of the dyed carpet are first sewn together to form acontinuous belt. This belt is then rolled under a dispenser that spreads

a coating of latex onto the bottom of the carpet.

At the same time, a strong secondary backing is also coated with latex.

Both of these are then rolled onto a marriage roller, which forms them

into a sandwich and seals them together. The carpet is then placed in

an oven to cure the latex.

The completed carpet is then steamed, brushed, vacuumed, and run

through a machine that clips off any tufts that rise above its uniformsurface. The carpet is then rolled into 120 foot (37 m) lengths that are

then packaged in strong plastic and shipped to either the carpet

manufacturer's inventory warehouse or to a retail carpet store.

Hand-made V/s Machine-made carpets


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Carpet is a textile floor covering that is fixed to the floor surface and

extends wall to wall. Such a textile floor covering is manufactured in

two ways: hand-made or machine-made.

One of the most prominent differences between hand-made and

machine-made carpets is that the former holds a valuable impression.

The other main difference between these two types of rugs is the

actual manner of construction. Machine-made rugs consist of plastic

derived fibers being glued onto a strong plastic base which makes

them initially very durable, but over time the adhesive degrades and

the fibers detach easily from the base.

It is said that for rooms with modern designs or active areas with high

traffic or children, machine-made rugs with contemporary designs are

excellent. On the other hand, there is a common misconception that

hand-made oriental rugs are delicate and not durable. Their ornate

designs and soft feel often deceive many.

More clarity on the differences can be explained in terms of:

Knots used Sides and Ends sewn

Back of the carpets

Materials used

Touch

Manufacturing process

Knots

Machine-made rugs and carpets are not woven by hand but areloomed by a computer generated system or apparatus. There are no

knots in machine-made rugs. Whereas in a hand-made rug, each knot

is hand knotted and tied. In machine-made carpets, threads are glued

or looped onto a hot latex (plastic) backing which cools and hardens.

They show a complete and rigid uniformity in manufacture which
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transforms into a static design. Machine-made rugs generally lack

spontaneity and human touch.

Carpet Knots

Hand-knotted pile carpets are the most durable in tenure. Tufted

carpets with different types of piles or loops are also available but

knotted are the best in the category. Usually an Oriental rug quality is

judged by the knots per square inch. The more the count, better the

quality.

Types

The most common types of knots used in an oriental carpet are:

Persian knot: It is an asymmetrical single knot also called Senneh knot

or Farsibaff. Here the thread forms only one loop around one of the

two warps. So the pile threads vary in protruding between the

adjacent warps.

Turkish knot: It is a symmetrical double knot type also called Ghirdes.

Here the pile thread forms a loop around two warps. Both ends of the

pile thread come out between both warps.

Jufti knot: It can be symmetrical or asymmetrical and the difference is

that it is formed over four wraps.

Tibetan knot: A temporary rod which establishes the length of pile is

put in front of the warp. A continuous yarn is looped around two

warps and then once around the rod. Once through with the row, the

loops are cut to form the knot.Moreover, each knot gives a different texture to the carpet.

Knot Density

Knot density is an indicator of quality. More the number of knots per

square inch, better the quality. KPSI is the density i.e. knots per square


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inch.

80 or less KPSI denotes poor quality

120 to 330 is medium to good

330 or more KPSI denotes good to very good quality and more than

that are classified as exclusively fine pieces.

Sides and Ends

In a hand-made or hand-knotted rug, the fringe is part of the rug. The

fringe is not sewn on as an extension, as is the case in machine-made

rugs. Machine-made rugs always have serged sides or machine

stitching on both sides of the rug, as opposed to a hand-knotted which

will be irregular and imperfect.

Back

In power loomed or machine-made rugs the stitching on the back is

very consistent. They have extremely regular knots and even structure

remains identical in all parts of the carpet. On the other hand, in hand-

knotted rugs the stitching varies slightly due to different tensions on

the wool as people hand-tie the knots. Most hand-made rugs andcarpets are covered with a cotton or canvas backing.

Materials

Acrylics and other chemically processed materials are usually used to

make machine-made carpets. Hand-knotted rugs and carpets use pure

organic wools.

TouchYou can also differentiate a machine-made and hand-made rug simply

by touching. If you place one finger on the front of a machine-made

rug and your thumb on the back and pinch tightly, the rug will

compress greatly and you will feel a sensation going right through one

side to the other side. On the other hand, while pinching hand-made


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rugs you will feel much more body and substance.

Careers in Carpet industry

There are umpteen jobs available in the market for any hard-working

and skilled individual. It is said that the career so chosen must be a

field of passion. In this competitive environment where everyone

wants to reach to the top, it is hard to determine which path to

choose. The bottom line is to know what you want to do, being

passionate about it and giving in your best to make it a success! Each

field has its relevance. No field can be compared to that of another.

Some areas that can be chosen by youngsters to pursue their careers

in the carpet industry are:

]

A Specifier's Rant: The "UN"standardized Carpet Industry

I just completed my umpteenth-hundredth carpet specification section

and Ive had itespecially when it comes to specifying for public

projects. As many of you may know, public projects typically require

open competition for projects, including the selection of products that

are specified. So, as a response, specifiers are typically tasked to

include a minimum of three products in the specifications to ensure

competition. So what is the problem? Actually, there are a couple of

problemshowever, if one is resolved, the other goes away.

The first problem is getting designers to select three acceptable

carpets. Since carpet is such a visual item, the specifier should not be

left with the job of finding two other carpet selections in addition to the

one selected by the designer. Selecting carpet is a mix of color,


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pattern, and performance. Carpet color and pattern are characteristics

that belong to the designer, but performance characteristics is the

area where the specifier livesand is the source of the second

problem.

The second problem is finding carpeting that has similar performance

characteristicsits like asking someone to find three similar marbles in

a barrel of marbles. And to compound the problem, there is no

standardization in the way carpeting information is presented

manufacturers' carpet data use inconsistent terminology and

inconsistent units of measurement (if they even bother to provide the

units of measurement).

For example, I see tufted weight, face weight, and total

weight. All have different meanings, but not all are provided in

manufacturers literaturemostly, they provide one or maybe two of

those characteristics. The Carpet and Rug Institute (CRI),

which shouldbe the leader in the industry, doesnt mention any of

those in their glossarywhat they provide is finished yarn weightis

this a fourth weight characteristic, or is it an alternative for one of the

previous three terms? I dont know, because the multitudes of online

carpet glossaries vary widely in their definitions, which make it difficult

to compare, and almost all dont define more than two of the

terms. Surprisingly, ASTM D 5684, Standard Terminology Relating to

Pile Floor Coverings, doesnt provide a single definition in regard to

weight!

Adding to the confusion is the frequent use of proprietary names by

manufacturers to describe components of their carpeting, such as fiber

and backings. So, how is a specifier (let alone a customer) supposed tocompare the construction and performance of carpeting if the use of

terminology by manufacturers is all over the map? This specifiers

answer: STANDARDIZE!


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Other building finishes use standards to either classify products or to

provide a minimum product specification. An example of a

classification standard is ASTM E 1264, Standard Classification for

Acoustical Ceiling Products. An example of a specification standard is

ASTM F 1303, Standard Specification for Sheet Vinyl Floor Covering with

Backing. Products complying with these standards are categorized

based on physical and performance characteristics. Therefore, two

products with the same type and grade (vinyl flooring), or type, form,

and pattern (acoustical ceilings), may not be equal, but they can be

considered comparable; thus narrowing the field of acceptable

products to ease the selection process for the designer or specifier, or

simplifying the substitution review process.

If the carpet industry would just sit down and create a logical method

to identify comparable carpet products, then all the specifier needs to

do is provide something like the following:

Carpet: Style B; Type III; Grade 3A.

Which could mean the following:

Style B: Tufted, multi-level loop

Type III: Woven primary with foam secondary backings

Grade 3A: 3 = Total density is greater than 1800 and less than or equal

to 2000 oz./cu. yd.

A = Critical radiant flux not less than 0.45 W/sq. cm

If other characteristics are important, such as fiber material and pile

thickness, then those could be added to the specification, along with a

basis-of-design product to establish a color and pattern to achieve.

Of course, to make such a standard worthwhile and beneficial to design

professionals, manufacturers would need to use the system in their

product literature. Also, measuring density would need to be

standardized through a standard test method.


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This may be a specifiers a pipe dream, but if the paint industry can pull

it off, so can the carpet industry. It took years, but a system was

developed to help categorize an ever-changing paint industry; the

system isnt perfect, but its a start. The carpet industry needs to take a

lesson from their fellow manufacturers of architectural finishes who

have standardized their respective industries and follow suit.

CARPET INSPECTION

Residential and commercial carpet inspections are required when there

are misunderstandings or complaints about carpet performance.

An IICRC-certified inspection is required by most carpet

mills/manufacturers, and may be requested by anyone who is in thecarpet value chain, including the retailer, installation contractor, end-

user or consumer. The inspectors job is to collect forensic evidence

about flooring problems and express his or her observations and

conclusions about that evidence in a clear and concise report suitable

for use in a court of law.

Questions regarding carpet performance generally fall into one or a

combination of the following categories:

Manufacturing Specification Installation Maintenance Misunderstanding of inherent product characteristics

Not only do cleantrust inspectors understand inspection, but they are

also required to have training and certification in carpet cleaning, stain

and spot removal, repairs and installation.

Maintenance


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CARPET MAINTENANCE & CARPET CARE TIPS

A regular carpet maintenance program extends the life of the original

appearance of your carpet. Today's carpet fibers are designed to hide

dirt and reflect light and have the ability to resist soiling and stains.

However, the lack of apparent soiling does not eliminate the necessity

of regular cleaning.

CARPET MAINTENANCE

For ideal carpet maintenance, you will need to vacuum your heavy

traffic areas, such as hallways, stairs, and exterior entryways at least

twice a week. Vacuum less heavily used areas weekly. For best results,

use a vacuum cleaner with a beater bar or rotating brush and with a

strong enough air flow to penetrate to the carpet backing.Carpet with thick loop pile construction, particularly wool and wool

blend styles, may be sensitive to brushing or rubbing of the pile surface

and may become fuzzy. For these products, and those styles with a

combination thick or thin or cable yarn, a suction-only vacuum is

recommended for the best carpet maintenance. If that is not available,

use or a vacuum with an adjustable brush lifted away from the carpet

so it does not agitate the pile. A vacuum with a beater bar or rotating

brush can be tested for excessive fuzzing in an inconspicuous location

before regular use.

Carpet One Floor & Home does not recommend a vacuum

brand.There are brands that offer adjustable beater bars or even a

feature to turn the beater bar off in some cases. The Carpet and Rug

Institute(www.carpet-rug.org) also offers information and ratings of

vacuums to provide the best new carpet care.

Most dry soil has razor-like edges that abrade carpet fibers, causing

light to reflect differently and give carpet a dull appearance. Soil can

damage the fibers permanently if allowed to remain in the pile. A

regular carpet maintenance program as well as proper carpet cleaning

methods will keep your carpet beautiful for a long time.


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CARPET CARE & CLEANING TIPS

No matter how often you vacuum, your carpet will still need heavy-duty

cleaning from time to time. Professional carpet care and cleaning is

required to maintain your Carpet One Floor & Home warranty. We

would be glad to advise you about which cleaning method is best for

your particular carpet. Hot water extraction carpet care, either alone or

in combination with cleaning, is required to maintain most warranties.*

Some styles, however, must be cleaned in other ways. Be sure to check

with your Carpet One Floor & Home retailer for the recommended

cleaning method for your particular carpet. A trained carpet care

professional should perform this service at least every 18-24 months to

refresh the texture and rejuvenate the fibers in your carpet. Have the

cleaning professionals come to your home for a visual inspection, and

obtain a written agreement before the work is started. You must retain

your receipts for proof of maintenance service should a warranty claim

arise.

When you and your carpet cleaning professional choose a cleaning

method, fiber content is the most important concern. Most carpet

today is constructed with synthetic fibers such as nylon, polyester, or

olefin and may be cleaned with most cleaning methods. Natural fiberssuch as wool, cotton, silk, and sisal may require specialized care. Use a

cleaning method recommended by the carpet manufacturer to

maintain their warranty, and if you should have any questions or

concerns about your new carpet care, just call your Carpet One Floor &

Home retailer.

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