How Carpet is Made Part 1

Written by creatingyourspace on . Posted in Carpet


Knowing how carpet is made can be very advantageous. Knowing the different materials that make up various carpets also helps you understand and evaluate their performance aspects: why certain carpets are easier to install, why some wear better, longer, and why others are easier to care for and clean. It can also make you a smarter shopper.

Selections:

  • thicker is not always better
  • tight twist in each yarn is better than loose and frayed
  • firm and dense pile means quality
  • the more backing seen, the less dense and durable
  • high traffic areas need lower profiles to avoid matting and crushing

Step 1: Fiber

  • basic material of makeup
  • 90% is synthetic fiber
  • rest is natural fiber, mostly wool

Synthetic Fibers

  • made up of one of three materials: nylon, polypropylene or polyester
  • created by chemical processes from oil and natural gas

Nylon

  • 75% is made of nylon
  • performs the best overall
  • leader in: appearance retention, fade and heat resistance, soil and stain resistance, color and styling
  • highest performance nylon is Type 6.6 for more resistant to stain penetration

Polypropylene

  • next most common material is polypropylene
  • introduced in the late 1950’s in Italy
  • BCF represents more than 35% of all fibers
  • not as resilient or resistant to abrasion as nylon
  • naturally stain and fade resistant
  • naturally resistance to moisture
  • more limited range of color options
  • most often used in loop pile constructions

Polyester

  • third type of material is polyester
  • introduced to the carpet industry in the mid 1960’s
  • well accepted for bulkiness, color clarity, and good stain and fade resistance
  • not as resilient as nylon
  • can be a good performer

PET

  • Mohawk makes from plastic bottles
  • plastic is collected, separated by color, and then ground and melted
  • used to manufacture the PET carpet fiber
  • carpets made by Mohawk of PET staple fiber made from 100% recycled material
  • great color clarity, stain resistance, durability
  • keeps over 3 billion bottles out of landfills

SmartStrand

  • made with DuPont Sonora polymer
  • DuPont and Mohawk make this fiber into carpet
  • SmartStrand with DuPont Sorona is continuous filament fiber
  • eliminates shedding
  • highly stain resistant and durable
  • 40% of the fiber made from corn by products

Wool

  • The above three materials make up the majority of synthetic fibers.
  • The other type of fiber used in carpet construction is staple fiber.
  • While some synthetics are used in the creation of staple fibers, the original staple fiber used in the making of carpet is wool.
  • The wool used in today’s carpet comes primarily from New Zealand, Argentina, and the United Kingdom.
  • Since wool is a natural fiber, it ranges in color from off-white to black, with many earthen tones between.
  • Wool doesn’t stand up to abrasion and moisture as well as synthetics, it cleans well and is known to age gracefully.
  • Wool is the most expensive carpet fiber, and represents less than one percent of the U.S. carpet market.

Berber

  • considered a type of carpet construction
  • actually comes from the name of a group of North African sheepherders called the Berbers
  • Berbers produced coarse wool, with color flecks in their yarns

 

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