The process of manufacturing machine-made carpets

 is a complex, multi-stage procedure that includes various stages, from raw material preparation to the final delivery of the carpet to the market. These stages are as follows:

 Spinning and Yarn Preparation.1 

   In this stage, raw fibers are converted into yarn. Three main types of yarn are used in machine-made carpets: pile yarn (the fibers or tufts), weft yarn, and warp yarn. After dyeing and twisting, the yarns undergo a heat-setting and twisting process to prevent shedding and to increase durability.

 Carpet Weaving.2

   In this section, the yarns are fed into weaving machines. Based on the carpet's design, the yarns are installed in the machine and woven using a face-to-face method. This process creates the carpet's three-dimensional structure. Advanced machines are used to weave carpets in various densities (700, 1000, 1200, 1500 knots per inch).

 Quality Control and Repair of the Raw Carpet.3

   After weaving, the carpets are inspected for defects such as streaking, broken patterns, or uneven surfaces. This process is performed by skilled experts and repair workers.

 Sizing and Finishing.4

   The raw carpet undergoes various stages, including cleaning the back, cleaning the surface, shearing, sizing, drying, and steaming, to increase strength, beauty, and durability. Finally, the fringes are sewn onto the carpet, and the edges are zigzag stitched.

. Final Quality Control.5

   After finishing, the carpet undergoes another inspection to ensure no defects remain.

 Grading.6

   Carpets are classified into different grades based on quality, with defect-free carpets being classified as grade one.

 Packaging.7

   The carpets are packaged in durable rolls and are wrapped in plastic covers for protection against potential damage.

 Storage and Distribution.8

   The carpets are stored in a warehouse and prepared for delivery to the market. In addition to physical stores, online sales have also gained popularity.

Summary:

The production of machine-made carpets is a precise and specialized process that involves spinning, weaving, quality control, finishing, grading, and packaging. The final quality of the carpet depends on the attention to detail in these stages, and by using high-quality yarns and advanced machinery, durable and high-quality carpets are produced.