Download - 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.