Bellbridge Carpet in Washington, DC

There are basically three steps to manufacturing carpet. The first step is tufting. Tufting begins with the process of weaving the synthetic or staple fiber into a primary backing material. The primary backing material is usually made of woven polypropylene, and its main value is to provide a base cloth to hold the yarn in place while the tufting happens.

Now the carpet is taken through one of two dyeing processes. The first method of dyeing is called yarn dyeing, or sometimes pre-dyeing, where the color is applied to the yarn prior to tufting. The advantages of all yarn dyeing methods include good side-by-side color consistency, large lot sizes, and uniformity. The second method involves applying color to the yarn after the carpet has been tufted. This method is called carpet dyeing. There are several carpet dyeing methods in use, each producing a unique end result.

In the finishing process, a coating of latex is applied to both the tufted, dyed carpet’s primary backing, and also to secondary backing. Secondary backing is typically made of a woven synthetic polypropylene material.The two parts are squeezed together in a large heated press, where they are held firmly to preserve their shape. Shearing, one of the last stages in the manufacture of carpet, is the process of removing all of the little loose ends and projecting fibers that might have been created during the tufting process. It also helps achieve the yarn’s tip definition of the finished carpet.

Finally, each carpet is carefully inspected for color uniformity and other manufacturing defects before it is rolled, wrapped, and shipped.