Rugs and Rubber Carpets Manufacturing

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Carpets are made by hand or machinery and come in varied designs, prices and texture. Carpets are generally textile covered flooring placed on the ground.

The manner of construction differentiates manual craftsmanship from machine generated rugs. Carpets are generally classified based on the type of fabric, woven technique and manufacturing process.

Traditional methods of carpet weaving have been used for centuries. Although hand woven carpets are still popular, machine carpets are more abundant.

 An entrepreneur interested in rug and rubber carpet manufacturing needs to decide on the manufacturing technique. You could decide to manufacture carpets through the aid of machinery or by hand.

  Handmade carpets attract premium prices and are major sources of income for artisans. To start a carpet manufacturing company you need to understand the various weaving techniques.

Other considerations are funding, equipment, trained staff, location and permits.

Starting a Rug and Rubber Carpet Manufacturing Business

Write a Business Plan

Start by writing a carpet manufacturing business plan. Then carry out a feasibility study manufacturer in your location.

Incorporate the business into a LLC and get insurance. Get a business license and other permits to facilitate production.

Find a suitable location, source raw materials and apply for bank loans. Hire appropriate staff, conduct market survey to ascertain type of product to manufacture.

Finally you need to put in place a good marketing strategy to sell your product.

Different Types of Machine Woven Carpets

Machines are capable of producing different kinds of woven carpets. The woven techniques include flocked carpets, kitted carpets and velvet carpets.

Other forms are Axminster carpets, Wilton and needle punching techniques. Machine made carpets have strong plastic based with threads looped or glued to base. The tension in machine woven fibers is consistent and even.

Raw Materials used to Make Carpets

Manufacturers use different material to make carpets. Many carpets consist of synthetic fibers such as polyester, acrylic and nylon.

Others have olefin, jute, bamboo and wool. Wool is the most commonly used fiber in the manufacture of carpets. Most hand woven carpet manufacturers use wool or silk fibers.

Machine Designs

Automatic weaving machines produce good quality designs and are durable. The designs are generated through a computing system and generated.

Automatic weavers are capable of intricate complex weaving patterns, efficiency and fast production.

The Difference between Machine made and Handmade Carpets

The differences manifest in the type of knots and fiber. Other differences are associated to raw materials, touch test and manufacturing process.

The loam in handmade carpets are sometimes irregular while machine made carpets are regular. Another difference is the sides and ends of the carpet.

Some manufactured carpets are glued to a base or attached through looming.

Manufacturing Tufted Carpet

There are different weaving methods used by automated machines. The machine is capable of manufacturing carpets through needle punching or knitting methods. Other methods used by machines are woven methods, flocked and tufted methods.

To prepare the yarn a continuous filament is spoon into a yarn and heated. The yarn is then fed into the machine that controls a tufted needle.

A photoelectric sensor controls the impression of the needles. The needles are synchronized to perform delicate piercing motions.

The yarn is either dyed before or after the tufted process depending on the manufacturer. Machines are capable of making solid colored carpets, printed carpets and dyed printed carpets.

The final stage involves sewing the ends of the carpet.

Manufacturing Process for Handmade Carpets

Handmade carpets attract premium prices because they are rare. Handmade carpets are made using one of the following methods.

The carpets are manufactured through braiding, weaving, knotting or tufting. Other techniques involve knotting, hooking, tying or shearing.

To produce handmade knotted carpet the wool is sorted and washed. This is to remove impurities and dirt.

Then the wool goes through carding and spinning into a yarn. The yarn is then dyed and looms knotted into carpets. The completed carpet is then trimmed, washed, dried and re-trimmed to perfection.
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Marketing the Carpets

Carpets are used in hotels, hostels, homes and offices. They are a popular piece of furnishing that adds beauty and elegance to the surroundings.

 Carpets are sold locally or exported to foreign markets. They are common in furniture stores, articulated markets and rug shops.

Sell your quality products to wholesalers and retailers. Showcase your products through social media or a website. Apply branding and don’t forget to advertise the product.