How Carpet is Made Part 2

Written by creatingyourspace on . Posted in Carpet

Carpet is made in a 3-part process.

#1 Tufting

  • begins with weaving the synthetic or staple fiber into a primary backing material
  • usually made of woven polypropylene
  • main value is to provide a base cloth to hold the yarn while tufting happens
  • tufting machine has 800 to 2000 needles like a sewing machine to pull the yarn through the primary backing material
  • tufting machine is 12 feet wide, its needles penetrate the backing and a small hook (looper) grabs the yarn and holds it in place

Loop pile construction

  • holds appearance well
  • no exposed yarn tips
  • only sides of the yarn are exposed to wear and stress
  • known to hold up the best

Alternative step

  • sometimes the looper cuts small loops creating a cut pile
  • length of these pieces called pile height, or distance between the looper and primary backing
  • cuts are controlled by a computer, and can be programmed to cut only some of the loops
  • this cutting is called cut and loop construction and creates pattern on the surface

#2 Application of dye

Two dyeing processes

  • yarn dyeing/ pre-dyeing -color is applied to the yarn prior to tufting
  • advantages are good side-by-side color consistency, large lot sizes, uniformity
  • carpet dying – applying color to the yarn after tufting
  • benefits -greater color flexibility, lower co

Carpet dyeing methods

  • Beck/ batch dyeing- stitching the ends together, then running the tufted carpet loop through large vats of dye and water for several hours.
  • Beck process ideal for small runs, heavier face weight products
  • continuous dyeing -similar to Beck dyeing – carpet is also run through processes other than dying
  • continuous dyeing – applies color to the face by spraying or printing, also to create multicolor or patterned effects
  • screen printing – color is applied through anywhere from 1-8 silk-screens.

#3 Manufacturing the carpet

  • finishing process- single production line that completes the final construction stages
    • coating of latex applied to dyed carpet’s primary and secondary backing
    • secondary backing – made of woven synthetic polypropylene
    • two parts are squeezed together in a large heated press and held firmly to preserve shape
  • shearing- removing loose ends and projecting fibers created during the tufting process
  • also helps the yarn’s tip definition
  • inspection – for color uniformity and defects before it rolled, wrapped, and shipped

Terms and construction variables

Pile height, or nap

  • length of the tuft measured from the primary backing to the yarn tips
  • shown as a fraction, or decimal equivalent
  • shorter pile is more durable than longer pile
  • stitch rate – measure of how close the yarns are together
  • stitch rate is measured in penetrations, or tufts, in a given length of carpet, usually an inch.
  • stitch rate is controlled by the speed the carpet is moved through the tufting machine
  • good number is seven to eight tufts per inch
  • face weight-actual amount of fiber per square yard, measured in ounces
  • typical carpet may have a face weight of 35 to 45 oz
  • density- how tightly the yarn is stitched into the primary backing
  • higher density will wear better than low density

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

 

Introducing Carpet

Written by creatingyourspace on . Posted in Carpet


Carpet is an ancient but beautiful idea. Modern carpet traces its roots to ancient times, when cultures passed hand-tying and knotting skills from generation to generation. The Sixteenth Century brought merchant adventurers and explorers home to Europe and with them the awareness and desire for rich textiles and rugs from the East. It wasn’t long before the appreciation of textile floor coverings took off, came to America, and became one of the most fundamental and beautiful parts of our modern home interior. Carpet continues to be popular for many reasons.

 

Primary flooring choice

  • relatively inexpensive
  • comfortable underfoot
  • easier to install and replace
  • fashion options to meet every style and décor’
  • warmer, softer and quieter

Carpet advantages

  • soft under foot
  • easy on kids knees
  • quieter than hard surfaces floors
  • wide variety of colors, tones and hues
  • easy to decorate with
  • hides sub-floor irregularities
  • can go over a variety of substrates
  • can go on all grade levels
  • economical and installation costs less than hard surface

 

How to Remove Chewing Gum from Carpet

Written by creatingyourspace on . Posted in Care and Maintenance, Carpet, Floors, Hints, Tips and Advice, Tips and Advice

14768658_SHave you ever had chewing gum stuck in your hair? In the worst cases you can cut the gum out of your hair, but have you ever gotten gum stuck in your carpet? It’s not such a good idea to cut the gum out of your carpet because unlike your hair, the carpet won’t grow back!

Below are some tips about how to remove chewing gum from your carpet:

Solvent – A non-flammable spot removal solution, or dry cleaning type solvent, is preferred. Exercise caution when using a solvent. Never pour it directly onto the carpet or allow it to reach the backing, because it can damage the latex that holds the primary and secondary backings together. Acceptable solvents include Carbona®, Energine®, K2R®, Goof-Off®, etc.

When in doubt, you can always call a Professional – Professional cleaners have the ability and the equipment to use more aggressive cleaning solutions to remove stubborn spills. Always consider consulting a professional cleaner regarding any spot removal question. The Carpet and Rug Institute – 1-800-882-8846

If you happened to have already had this problem and now have a hole in your carpet, we can talk about a replacement!

Penny Wise

Written by creatingyourspace on . Posted in Carpet, Design and Decorating, Floors, Hints, Tips and Advice, Tile and Natural Stone

The old saying “penny wise and pound foolish” can certainly be applied to home decorating. Putting your budget and money towards investments is wiser than skimping on the big decorative elements and splurging on trendy accents.  When it comes to decorating or remodeling it is important to be more pound wise and penny foolish.

Decorating and designing your home can be a costly endeavor. Whatever budget you have for decorating, putting your money where it counts and will make the biggest impact is key.  Flooring and furniture are two areas where money spent can be a good investment.

Buying the best quality flooring, whether you prefer carpet or tile, is an investment that should last for years in your home. Furniture purchases are the same.  A well constructed sofa or chair, a good quality mattress and bed frame, can last for years of use without showing its age.

Upholstery and rugs are two more important places to spend money.  Invest in durable materials and good quality that can stand up to the wear and tear of everyday living in your home. Accent fabrics and pillows can be trendier as they are easier and less expensive to replace.

Follow the trends with accents and inexpensive DIY projects that can emulate more expensive items. Pillows, decorative objects, and paint for the walls can transform a tired décor without spending a great deal of money.  Save your pennies for the big expenses and investment pieces that will last you for years.

How Often Should I Clean My Carpet?

Written by creatingyourspace on . Posted in Care and Maintenance, Carpet, Tips and Advice

After adding beautiful new carpet to your home it is necessary to know how to take care of it for reasons of longevity as well as appearance. Just vacuuming your carpets is not enough, which of course, raises another question: how often should you vacuum your carpet. Areas that receive a lot of foot traffic will need to be vacuumed daily or twice weekly, depending on the number of feet walking your carpet. Other carpeted areas may only need to be vacuumed once a week if they receive less traffic.

But back to the original question: how often should I clean my carpet? Carpet no matter what type holds many things, dust mites, dirt, pet hair, odors and stains. Each carpet will need to be cleaned differently depending on several things. For instance you wouldn’t want to handle a cheaply made carpet as often as you could a wool rug. Each time a carpet is cleaned it gets broken down a little and so it is important to know the quality of the carpets to be cleaned before actually doing it.

If you live alone with nothing other than normal environmental factors to dirty your carpets, cleaning them once a year should be sufficient. If you smoke, have pets or children or if the carpet is in a high traffic area it should be cleaned every six to nine months depending on how exposed it is. If you live in a dusty or a humid area it can have an effect on your carpet’s cleanliness. Even if it seems there is nothing in your home to dirty the carpets you must remember all of the invisible invaders which are in your carpet. If for no other reason than a healthier environment, have the carpets cleaned annually.

 

Getting Mustard Out of Carpet

Written by creatingyourspace on . Posted in Care and Maintenance, Carpet, Hints, Tips and Advice

One of the hazards of having a BBQ and carting food items and dirty plates back into the house after dinner is the inevitable chance of a spill. One of the hardest stains to get out is mustard. Since mustard contains tumeric, which is a bright yellow color, it can be a real hassle to get out of carpet, especially white carpet. But don’t give up hope, we can help.

Act quickly – if you see the spill happen, work on it immediately.

Fold a paper towel into a 4-inch square and use it to dab at the area of the mustard spill. Remove as much of the spot as you can in this manner. Always do this before the stain has a chance to dry. If it’s too late, try to scrape as much of it off the carpet’s surface as you can with a dull knife.

Mix together your cleaning solution.  Add one cup of white vinegar per two cups of water to your bowl. Stir with the mixing spoon. Then carefully pour the mixture into the spray bottle.

Before you apply any cleaner, including the one in these directions, to your carpet, test the cleaner in a small patch where no one will see it. Wait a few minutes. If the cleaner discolors or otherwise adversely affects the carpet, remove it immediately with cold water and a sponge. If it ends up causing permanent damage, at least it won’t be right in the middle of the room.

Hold the spray bottle 6 inches above the stain and spray until about a half inch of foam is sitting on the carpet where the stain is present. Blot the stain with a clean white cloth. Continue to blot until you cannot see any more mustard. Spray solution as needed.

Blot the spot with a new, clean cloth to remove any excess cleaning solution. Then rinse the cloth in lukewarm tap water and scrub out any remaining solution.

If you cannot remove the stain, call a reputable carpet cleaner as soon as possible.

Again, act as quickly as possible. And please don’t let the fear of a spill stop you from entertaining.

White Carpet and Furniture with Kids and Pets?

Written by creatingyourspace on . Posted in Carpet, Family, Floors

Does the idea of white shag carpet in a house with kids or pets make you shudder? Many people avoid white carpets and white furniture when they have kids and pets. If you have the perfect children and the perfect pets who never spill or track in dirt, you might be fine with all white carpet or furniture. Is white really off limits for the rest of us? With today’s high tech fabrics and stain protectors, white can once again be a choice for furniture and flooring, even with those messy pets and kids.

Taking off shoes and avoiding tracking in dirt and water from outside is a good habit to get into for any flooring. Preventing the dirt from being brought into the home will put you ahead of the game when it comes to battling dirt. Blotting and treating spills and stains as they happen is also a good habit to get into whatever your carpet or flooring. Home steamers and steam cleaners are more readily available and more effective.

If you love the look of white furniture, consider slipcovers. White cotton slipcovers can be custom made or bought premade in a variety of sizes and styles. If you make a custom slipcover yourself or have it made by an upholsterer, you will get the best fit for your sofa or chair. You can choose a slipcover with a skirt that is box pleated, ruffled or straight; or one that does not have a skirt and exposes the legs.

Cozy Cubby

Written by creatingyourspace on . Posted in Carpet, Design and Decorating, Hints, Tips and Advice

This boy found the perfect place to read in privacy and comfort. The soft carpeting provides cushioning and this space allows him to settle into the perfect position to support his literary habit.

Do your children have a special space to get comfortable and read? It may be a cubby like this, a window seat, or a child-proportioned easy chair and ottoman. If not, how about creating a corner to encourage reading?

You need three things to make this work in your home, none of which involve a lot of space or money.

First: select a spot – preferably with your child or children – that is quiet and set away from everyday noises. It can be a corner of a guest room, basement or living room. The goal is finding a peaceful location.

Second: make sure there is adequate lighting. This may be available with an overhead light, a floor lamp or even a table lamp set in the right spot. The light should come over the back of your child’s shoulder so the pages are not in shadow.

Finally, make sure the space has either a comfortable chair or some cushions to enable your child to position him or herself at just the right angle for some long-term reading. This little guy seems happy with just the carpeting, but a pillow behind his back would probably make the space more comfy. Remember, your goal is to encourage your children to read, so a special place like this can provide encouragement.

Choosing the Right Flooring for You

Written by creatingyourspace on . Posted in Area Rugs, Carpet, Hardwood, Hints, Tips and Advice, Tile and Natural Stone, Vinyl

There’s no hiding how this store perceives itself. Check your wallet before you walk in – if it’s too thin, walk on by.

Most of us would not be drawn to a store that promotes itself as expensive. High prices are not the same as high quality, and the focus should be on quality and value, not just the “bottom line.”

When it comes to flooring, often people perceive many choices as expensive. In reality, there is almost as wide a variety in flooring materials, construction and workmanship as there is in clothing. When you’re making purchasing decisions, it’s important to look beyond price to find the quality and style you want and determine the true value of your choice.

Sometimes a silk shirt is the right choice, and for other purposes, cotton may be better. Silk is more expensive than cotton in general but it might be just right with the outfit you’re planning so you’re willing to pay more. In the same way, one flooring material may be more expensive but worth the price for your purposes.

When you’re debating about the right flooring for you, how about taking the cost difference between the two options and dividing it by the number of years you plan to live in your home. Are you willing to pay that much more a year for the more expensive flooring? If you plan to move in a few years, take a look at resale issues. For example, homes with wood floors sell faster than homes with any other type of flooring.

When you’re choosing flooring, don’t discard price issues, but be sure to look beyond cost when you make your final choice.