With advances in manufacturing technology, 95% of all carpet produced today is tufted. It takes about an hour to make a roll of carpet that might take eight hours to weave. To make tufted carpet, hundreds of yarn-threaded needles are pushed through the primary backing fabric to form loops or tufts, which may be left as is or cut.
A heavy adhesive coating is applied to hold the tufts in place and a secondary backing is usually glued on for strength and stability. A wide variety of styles and textures can then be created using various techniques.
Woven carpet may be in a tiny minority of today’s production but still produces some of the finest carpets which are used for prestigious installations.
Axminster – The pile of the carpet is inserted into the backing as it is woven and cut to length, creating U-shaped tufts to give a velvety surface. The process locks in the fibre to create a carpet of high durability and performance retention as well as a luxury feel. The process allows for intricate designs and colours to be used – although modern trends mean that the traditional patterned axminster has given way to current fashion trends for plain carpets.
Wilton – Wilton woven carpets are produced in a similar way to axminsters – the principal difference being that a continuous fibre is woven all the way through. The carpet can be sheared to create a range of cut and loop textured effects. The result is a high quality carpet of unrivalled durability.
Flat weave – Manufactured in the same way as wilton, flat weave is a loop pile which allows the yarn to be woven across a wider area to created a flatter, more textured effect.
Needlefelt – These carpets are produced by intermingling and felting individual synthetic fibres using barbed and forked needles forming an extremely durable carpet. These carpet ranges are normally made for the contract market such as Hotels, Schools, offices etc where there is a lot of foot traffic.