CUSTOM CARPET
1. HAND TUFTED
The process for creating a hand-tufted rug differs greatly. It is made by punching strands of wool into a canvas that is stretched on a frame with the help of a hand-operated tool. This process is not very time-intensive and does not require the same level of skill that hand-knotting does.
After piling with wool, the rug is removed from the frame, and a scrim fabric is glued to the back. To complete the rug, a fringe is added by either sewing or gluing it on.
The hand-tufted technique offers endless possibilities in design. All kind of textures, such as high pile and low pile, cut, loop and tip-shear, can be applied. A 3-dimensional effect can even be achieved, as the carving is done entirely by hand. The pattern can be non-repetitive, as the hand-tuft technique does not stop the design.
The entire artwork is printed onto a cloth, which is then stretched tight in a vertical frame. Meanwhile, the raw materials are dyed to the right colour. A special compressed-air gun shoots little U-shaped tufts of wool, bamboo or silk through the cloth, filling in the pattern with the right colours. This tufting gun is fitted with tiny scissors to determine the pile height. The sooner the tufts are clipped, the lower the pile height. After tufting, a reinforcing latex backing is added. The carpet then goes to the finishing department where the pile is sheared to the right height. Hand carving and/or pencilling further emphasises the patterns.
(1) HAND-TUFTED ( RUGS & WALL TO WALL ) |
: 100% Wool : 100% Acrylic : 100% Rayon/Bamboo |
56 oz |
72 oz |
88 oz |
104 oz |
2. AXMINSTER CARPET
In an axminster gripper weave, cut tufts of yarn are inserted at the point of weaving by means of grippers. For each tuft to be inserted along the width of the axminster carpet, there is a corresponding metal gripper which rises from the bed of the loom to grip the appropriate coloured end of yarn from the vertical yarn carrier. A knife blade slices the tuft to the correct length, the gripper then returns to the bed of the loom and places the tuft in the appropriate position, the weft shots of the backing yarns then bind it into place.
A beater bar pushes each row of tufts and weft shots tightly against one another to form the carpet. The “beatup” (rows) can vary from as low as 5 to 14 rows per inch, or even higher if required. Different coloured ends of yarn (according to design) can be selected from the yarn carrier, which is raised or lowered by means of a jacquard (punched card) mechanism. Many different colours can be used in this weaving method. More modern looms have electronic jacquards which enable them to produce very complicated designs with almost infinite pattern repeats.
(2) Axminster Capet |
: 80 % Wool :20% Nylon 66 |
Polyester – Cotton |
7 x 7 x 8 : 33 oz |
7 x 8 x 8 : 38 oz |
7 x 9 x 8 : 43 oz |
7 x 10 x 8 : 48 oz |
7 x 11 x 8 : 52 oz |
7 x 12 x 8 : 57 oz |
3. CHROMOJET PRINTING CARPET
The CHROMOJET family of digital printing systems is suitable for all kinds of pile products in a range of 300 up to 1,500 g/sqm. The printing machine is usually equipped with 8 to 16 individual colors. Special machines may have up to 48 colors. For printing, these colors are pressurized (1-3 bar) and supplied directly to the jets, which are electromagnetically opened and closed up to 1,200 times per second. The jets inject the dye with surgical precision deep into the face of the pile, without any machine parts touching the fabric surface. Best application for Floor covering products like Wall-to-Wall Carpets, Rugs, Carpet Tiles, and Mats. Special treatment can be applied to aid stain resistance to protect the carpet from any stains.
(3) Chromojet Printing |
100% Nylon |
32 oz |
36 oz |
Digital Print 270 gr |
Custom Weight |
STOCK CARPET
4. SISAL CARPET/RUG
Sisal carpet is a natural carpet fiber extracted from Agave plant’s long spiny leaves (species Agave sisalana). Sisal is a highly durable carpet often used in heavy traffic areas and higher end homes. It can be used as a wall to wall carpet, an area rug or runner. Often, sisal area rugs and runners are bound with a canvas border (about an inch wide) for a more tailored finish. In Westchester County NY, sisal has been rapidly growing in popularity. Sisal is also used for rope, twine, cloth, paper, handicrafts and wall coverings.
Many prefer sisals because of their earthy tones, their high end “berber” look/feel and because they hold less allergens. They also love that they are durable and tend to hide dirt/stains.
Because sisal is made entirely of natural plant fibers, it reflects the irregularity found in nature. A perfectly uniform floor covering is not possible using natural sisal fibers. Weaving variations – including knots, slubs, lines and color variances – are an inherent and desirable property of sisal.
5. CARPET TILE
Carpet tiles, also known as modular carpets, are a type of flooring which can be used as an alternative to the more common rolled carpet. They are formed from an upper layer of pile attached to a backing and are produced in a variety of sizes, materials, fibres, patterns and colours. Carpet tiles are often used in commercial and public buildings such as airports, offices, schools, libraries, and so on.
Carpet tiles are manufactured in both non-adhesive (require gluing) and adhesive (peel-and-stick) styles. When choosing tiles, it is important to consider the overall design scheme and the requirements of the finished floor, as well as the size and durability of the tiles required.
Some of the benefits of using carpet tiles include: They can be easier to install than rolled carpet. They can be installed over many floor types, including timber and concrete. Individual tiles can be removed and replaced for cleaning or if they get damaged. Creative patterned designs can be achieved. Many tiles are manufactured with good stain resistant properties.
6. MACHINE TUFTED IN VARIOUS STYLES
Machine-tufted carpets are made when the tufts, clusters of yarn fibers, are drawn through and inserted into a primary backing. A secondary backing is then adhered to the primary backing with a coat of latex, effectively laminating for a 2-dimensional construction.
These machines are capable of tufting loop, cut or both cut and loop, and with or without the tip-sheared effect, thus providing guest rooms with the desired softer look and feel. Using stitch by stitch control, these machineries offer precise design capabilities and improved pattern clarity. Both products accommodate custom weights, manufacturing widths, and a complete range of backings in order to meet the needs of an installation.
