How Tufted Carpet is Made

Tufting involves using a tufting gun or a punch needle to push yarn through a primary backing material, creating loops or cut piles that form the rug’s surface.This versatile process gives you the freedom to play with intricate designs and different kinds of texture.  The result is a piece of art that ticks the boxes as both decorative and functional

The newly formed tufts are held into place by the stitch holding capacity of the primary carpet backing material. Stitch holding is the force required to remove a loop from a greige carpet from the back side. It determines how strong the interaction is between the primary carpet backing and the tufting yarn. The primary carpet backing should exhibit good tuft holding characteristics.

A tufting machine is essentially a huge sewing machine with hundreds of needles that insert loops of yarn into the primary backing. Yarn is fed from a creel, one tube of yarn for each needle, and threaded through the needles. The tufting machine is set up to produce level loop, multi-level loop, cut pile, and cut and loop pile structures. The tufting machine's needles punch the yarn through the primary backing, which is fed into the machine from the rear.

Carpet Production：

• All tufted carpets including cut pile start out as a loop.
• For cut pile carpet the loops are cut during the tufting process.
• The face of the carpet is sheared to its desired effect and a secondary backing is applied to the carpet.
• This secondary backing will give the carpet its stability and allow it to be stretched during the installation process.
• Some tufted carpets are manufactured using pre-dyed yarn.
• Some synthetic yarn is solution dyed with the color built into the formulation.
• Other yarn is produced and then predyed using methods suck as skein dyeing.
• Most tufted carpet is manufactured using a greige yarn (undyed yarn). The carpet is dyed following the tufting.