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TYPES OF CARPET

Carpet industrys major products are

hand-knotted and hand tuftedcarpets. Hand-tufted carpet market is

growing rapidly. Some of industry

players believe that market is being

shifted from hand knotted segment

to hand-tufted segment. However

many players believe that both

products are targeted at Different

markets. Additionally, hand-tufted

carpets have already entered in to

home-furnishing segment. Following

chart shows the product wise market

share in Indian exports If one dissects

the market, some interesting facts come to fore. The export destinations can be categorized

onthe basis of potential.

1. Woven

2. Needlefelt

3. Knotted

4. Tufted

5. Flatweave

6. Hooked rug

7. Embroidery

8. Knotted Pile Carpet

Fibres and yarns used in carpet

Carpet can be made from many single or blended natural and synthetic fibres. Fibres are

chosen for durability, appearance, ease of manufacture, and cost. In terms of scale of

production, the dominant yarn constructions are polyamides (nylons) and polypropylene

with an estimated 90% of the commercial market.

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1. Nylon:

Nylon is the most common material for construction of carpets. Both nylon 6 and nylon 6-

6 are used. Nylon can be dyed topically or dyed in a molten state (solution dying). Nylon can

be printed easily and has excellent wear characteristics. In carpets Nylon tends to stain

easily because it possesses dye sites on the fibre. These dye sites need to be filled in order

to give Nylon any type of stain resistance. As nylon is petroleum-based it varies in price with

the price of oil.

2. Polypropylene:

Polypropylene is used to produce carpet yarns because it is inexpensive. It is difficult to dy e

and does not wear as well as wool or nylon. Polypropylene is commonly used to construct

Berber carpets. In this case, polypropylene is commonly referred to as olefin. Large looped

olefin Berber carpets are usually only suited for light domestic use and t end to mat down

quickly. Berber carpets with smaller loops tend to be more resilient and retain their new

appearance longer than large looped Berber styles. Commercial grade level -loop carpets

have very small loops, and commercial grade cut -pile styles are well constructed. When

made with polypropylene these styles wear very well, making them very suitable for areas

with heavy foot traffic such as offices. Polypropylene carpets are known to have good stain

resistance but not against oil based agents. If a s tain does set, it can be difficult to clean.

Commercial grade carpets can be glued directly to the floor or installed over a 1/4" thick, 8 -

pound density padding. Outdoor grass carpets are usually made from polypropylene.[7]

Wool and wool-blendsWool has excellent durability, can be dyed easily and is fairly

abundant. When blended with synthetic fibres such as nylon the durability of wool is

increased. Blended wool yarns are extensively used in production of modern carpet, with

the most common blend being 80% wool to 20% synthetic fibre, giving rise to the term

"80/20". Wool is relatively expensive and consequently a small portion of t he market.

3. Polyester:

The polyester known as "PET" (polyethylene terephthalate) is used in carpet manufacturing

in both spun and filament constructions. After the price of raw materials for many types of

carpet rose in the early 2000s, polyester became more competitive. Polyester has good

physical properties and is inherently stain -resistant because it is hydrophobic, and, unlike

nylon, does not have dye sites. Color is infused in a molten state (solution dyeing). Polyester

has the disadvantage that it tends to crush or mat down easily. It is typically used in mid- to

low-priced carpeting.

Another polyester, "PTT" ( Polytrimethylene terephthalate) , also called Sorona or 3GT

(Dupont)or Corterra (Shell), is a variant of PET. L urgi Zimmer PTT was first patented in 1941,

but it was not produced until the 1990s, when Shell Chemicals developed the low -cost

method of producing high-quality 1,3propanediol (PDO), the starting raw material for PTT

Corterra Polymers.

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4. Acrylic:

Acrylic is a synthetic material first created by the Dupont Corporation in 1941 but has gone

through various changes since it was first introduced. In the past Acrylic used to fuzz or pill

easily, this happened when the fibres degraded over time and short strands broke away

with contact or friction. Over the years Acrylics have been developed to alleviate some of

these problems although the issues have not been completely removed. Acrylic is fairly

difficult to dye but is colourfast, washable and has the fe el and appearance of wool making

it an ideal rug fabric.

5. Carpet binding:

Carpet binding is a term used for any material being applied to the edge of a carpet to make

a rug. Carpet binding is usually cotton or nylon, but also comes in many other materials,

such as leather. Non-synthetic binding is frequently used with bamboo, grass, and wool

rugs, but is often used with carpet made from other materials.

Carpet Manufacturing Process:

y Hand Made carpets:-Hand-made carpets are traditionally more expensive than those made by machines.

Though there are several carpet-making methods, including braiding, hand tying (or hand

knotting), hooking, shearing and tufting, the most common of these are braiding and hand

knotting.

Braided carpets are done by connecting or t ying strips of fabrics together. Hand tying or

hand-knotting are usually done on rugs. Countries that are known to produce beautifully

crafted hand-knotted rugs include Spain, Portugal, India, Pakistan, Turkey, Afghanistan and

Japan (among others). Hand-knotted rugs are descendants of Oriental Rugs and can be

made in any shape, size, coloured or design.

Process

The process that creates a hand-made/hand-knotted carpet can be explained as under:

Wool sorting & Washing

Wool is either imported or is bought fro m nearby markets and is

carefully sorted to pick out unwanted particles. Wool often carries

dust, grease which is removed by washing it thoroughly and is

then sun dried for two-three days.

The Tibetan wool has a strong good fibre length is imported inscoured form, good lustre and a high resilient value. The New

Zealand wool is of 36 micron, 100 mm barb length and is identified

as type 128. British wool meeting regulatory standards have also

started being available in the market.

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Carding

The carding process allows the fibre stand to flow smoothly when

spinning. This is also the stage for blending different wools and to

ascertain the ratio of different origins. Traditionally, carding was

performed by hand and machine carding was introduced when the

industry grew. However hand carded product is still available if a

customer so desires.

Spinning

The carded wool is spun into yarn by using a charkha or a spinning

wheel. The thickness of the yarn depends on the quality of the

carpet and generally a 3 ply yarn is used.Dyeing

The traditional pot dyeing method has been largely replaced by

machine dyeing in closed Chambers. Dyes containing harmfulsubstances such as AZO are banned and dye-stuffs from renowned

international manufacturers are used. These dyes have a high

degree of fastness. Depending on the weather, the dyed yarn has

to be dried in the sunlight for one to three days. Pot dyeing and

vegetable (natural) dyeing are still being used by some

manufacturers.

Carpet Knotting

Knotting is an art. Weavers who weave on a regular basis have a

very good speed in knotting. They tend to develop this speed over

a span of time. One or more weavers work on a loom depending

on the size of the carpet. Each weaver makes individual knots row

after row. The designs are chartered out on a graph and a map

reader or another weaver instructs the graphic designs to the ones

knotting the carpet. The dyed yarn is made into balls and scissors,

iron rod, levers; comb beaters are used as tools. Trimming

The finished carpet is taken off from the loom and the designs &

patterns are trimmed by scissors.

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Washing and Drying

The trimmed carpet is washed with the fresh water & chemicals.

The washed carpet is dried in the sunlight up to four or five days.

FinalTouches

The dried carpets are given final touches by re-trimming and

stretching, where ever necessary. The purpose is to bring the

fabric woven in level at the surface .

Packing

All washed carpets are rolled and wrapped in polythene sheet and

is sealed at each end. Again, it is wrapped in Hessian cloth and

sewn. Generally, around 14m2 are packed in each bale. Payment

Export proceeds must be received through an irrevocable letter of credit (L/C) or advance

payment

y Machine Made carpetMachine-made carpets are tufted, woven, knitted, flocked or needle-punched. Most

commonly tufting is used for machine-made carpets. Tufted carpets are made on

machines where the yarn is stitched through a pre-constructed backing to form a

loop or a tuft. To hold the loops in place, the back side of the carpet is coated with

latex.

Tufting is the most inexpensive and fastest ways to manufacture a rug. Weavers can

also control the tuft size making it possible to create carpets with varying patterns or

surface textures.

There are three kinds of woven carpets: Velvet, Wilton and Axminster. Velvet is the

least complicated of construction methods. Velvet carpets usually come in one solid

coloured and a tweed effect may be noticed. Wilton carpets are more intricate.

These are manufactured by using a Jacquard loom which can hold up to six different

coloured of yarns. The Axminster method of weaving carpets produces the most

elaborate designs with a wide variety of coloured.

Knitted carpets are faster to make. In knitting, several sets of needles create loops

and these are stitched together before the backing is applied. Knitted carpets come

in solid or tweed and the pile may be of the same size or of varying heig hts.

Flocked carpets are similar to Velvet carpets in appearance. They have a dense cut

pile of short fibres that are imbedded into an adhesive -coated backing.

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Needle-punching is similar to hand-hooking. Formerly used for indoor -outdoor

carpets, this process is now being used for carpets that are only meant to be placed

indoors as well. In needle-punching, fibres are locked into a packing by using hooked

needles, which are further compressed.

The Manufacturing Process

The process of manufacturing tufted carpets can be explained in the following steps:

Step 1: Preparing theyarn

First, the synthetic yarns arrive at the carpet manufacturer either in staple fibre

form or in bulk continuous filament form

The staple fibres, which are an average of 7 inches (18 cm) long are generally loose

and are individual strands that arrive in bales. Several bales are blended together

into one batch in a hopper.

Then, these strands are lubricated and are spun into long, loose ropes called slivers

by a carding machine. The slivers are then pulled, straightened, and spun into single

yarn that is wound onto spools.

Both the single-ply staple fibres (now spun into filament) and the bulk continuous

filament is then twisted together to form thicker two -ply yarn suitable for tufting.

The yarns are then steamed to bulk them, and then heated to 270 -280F (132-

138C). This heat setting causes the yarn to maintain its shape by fixing its twist.

After cooling, these yarns are wound onto tubes and transported to the tufting

machines.

Step 2: Dyeing theyarn

Generally, most carpets are dyed after tufting yet sometimes the yarns are dyed

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first. The methods include putting 500 -1,000 pounds (227 -455 kg) of fibre into

pressurized vats through which treated dyes are circulated, or passing the fibre

continuously through the bath, or passing skeins of yarn through the vat of dye.

The yarn can also be put on forms, and the heated dyes can then be forced under

pressure from inside the forms to coloured the yarn.

Another method passes the yarn through printing rollers, while yet another

involves knitting the yarn onto a form that is then printed with dyes before the yarn

is unravelled. All yarn that has been dyed is then steamed, washed, and dried .

Step3: Tufting the carpet

At this stage, the yarn is put on a creel (a bar with skewers) behind the tufting

machine and then fed into a nylon tube that leads to the tufting needle.

The needle pierces the primary backing and pushes the yarn down into a loop.

Photoelectric sensors control how deeply the needles plunge into the backing, so the

height of the loops can be controlled.

A looper, or flat hook, seizes and releases the loop of yarn while the needle pulls

back up; the backing is shifted forward and the needle once more p ierces the

backing further on.

Inorder to make a cut pile, a looper facing the opposite direction is fitted with a

knife that acts like a pair of scissors, snipping the loop. This process is carried out by

several hundred needles (up to 1,200 across the 12 foot [3.7 ml width), and several

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hundred rows of stitches are carried out per minute. Thus, one tufting machine can

produce several hundred square yards of carpets per day .

Step 4: Dyeing thetufted carpet

Solid coloured carpeting: For this carpet of several standard roll lengths is sewn

together to make a continuous roll, which is then fed into a vat. The vat is filled with

water, which is firstheated before dyes and chemicals are mixed in. The mixture isthen slowly brought to a boil and cooked for four hours approx.

Another method of making solid coloured carpet is to sew several rows together to

make one continuous roll, which is then fed under rods that bleed the coloured into

the pile. After dyeing, the carpet is then steamed to fix the colour ed, excess coloured

is washed off, and the carpet is dried and put on a roll.

Printed Carpets: Inorder to make printed carpet of various designs, white carpet

passes under screens in which holes in the desired pattern have been cut. The

desired coloured is squeezed through the

holes in the screen, and the carpet is

advanced 36 inches (91 cm) to a different

screen that applies a new coloured in a

different design through the screen. Up to

eight coloureds can be applied with this

method.

Another method of dyeing printed

carpet is to pass it under embossed

cylinders that have raised portions in a

design that press colour into the carpet.

Each cylinder provides a different design

for a different coloured. After dyeing, the

printed carpet is steamed, excess d yes are washed off, and the carpet is then dried

and put onto rolls to go to the finishing department .

Step 5: Finishing the carpet

The ends of the dyed carpet are first sewn together to form a continuous belt. This

belt is then rolled under a dispenser that spreads a coating of latex onto the bottom

of the carpet.

At the same time, a strong secondary backing is also coated with latex. Both of these

are then rolled onto a marriage roller, which forms them into a sandwich and seals

them together. The carpet is then placed in an oven to cure the latex. The completed carpet is then steamed, brushed, vacuumed, and run through a

machine that clips off any tufts that rise above its uniform surface. The carpet is then

rolled into 120 foot (37 m) lengths that are then packaged in strong plastic and

shipped to either the carpet manufacturer's inventory warehouse or to a retail

carpet store

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Pricing of the Industry:Carpet Industry is one of the prime industries that is entirely demand -driven. Indian carpet

Exporters basing on demand are now manufacturing woollen hand tufted carpets that has a

ready demand abroad. It was surprising to learn that exporters did not manufacture for the

domesticmarket. Demand at home is minimal because of the tropical climate that I ndia has.

Also, carpets are one of the high end furnishing items for a middle class Indian. For example,

we found during oursurvey, a medium quality, average sized [5 feet by 8 feet] carpet will

cost around INR 25,000-30,000 [USD 542- 651]. The price of Indian made carpet thus

becomes comparatively high forIndian households. Moreover these days competition from

machine made Belgium carpets pricedat around INR 3000-4000 [USD 65- 87] caters for

demand at home. Different exporters adopt different modes of pr omoting their products.

Generally they prefer topromote exports by visiting overseas customers frequently,

exhibiting its products in Internationaland Indian Carpet Fairs and approaching foreign

customers with carpet photographs and exportpromotion catalog ues. They regularly

produce new samples for the markets. A hand tufted averagesized carpet of 5 feet by 8 feetcan be woven within 2-3 days if two weavers are employed.Following the weaving, another

two-three days goes in washing and latexing (the rear of the carpet

is smeared with rubber to increase the longevity and durability of the carpet). Once the

carpets goesthrough these processes a final trimming of the carpets surface is done to bring

about theuniformity after which the carpet is ready to be pac ked and exported. The entire

process rangesfrom 7-10 days depending upon the number of hands being employed.

Usually, two labourers do washing and latexing respectively. For trimming an average sized

carpet one or two persons can beemployed.Once the carpet is packed, it is loaded onto

trucks for its destinations overseas. Usually, theMumbai port is used for exporting.

Sometimes, to meet urgent orders exporters send across theirgoods by air also, in such caseNew Delhi airport is used for transit. The transp ort costs go up when

air transport is availed, hence it is only used in emergency or when delay in delivery

happens because of some management/production glitches. The exporters had negligible

grievance oncustoms proceedings. They reported that delay in exports because of customs

and other bureaucratic procedures were at a minimum

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Why Panipat:

Bhadohi can easily claim to be the home of some of the richest carpet exporters in India.

Despite this, there are no proper roadways to and from the city. The road leading to Bhadohi

from the statehighway is rickety and gives the traveller a nice bumpy ride into the carpet city

of India. Electricity supply is on an average for 6 -7 hours on a day, though most of the time

low voltage prevails. In the evening hours the town is shrouded in dar kness, where only light

comes from lanterns, low-voltage bulbs or the car headlights. But as soon as one steps into

the exportersmansion, the scene changes. The power supply from the generators ensures

continuous electricity supply in the exporters mans ions. Apart from road, electricity, water

supply is also irregular. People have wells or deep tube wells for water supply. Though there

are ponds and other water bodies near Bhadohi, but the exporters said that the chemicals

used in dyeing pollutes the wat er. The State Government is not taking any active role in

improving the infrastructural facilities in thismajor export -earning cityCarpet Production

needs uninterrupted power supply, and the generators provide this power. One of the

exporters engaged in this business for the last 40 years, lamented the misuse of human and

financial resources because of the governments inefficiency in providing uninterrupted

power supply to Bhadohi exporter. The story is as follows:

On an average, a generator runs for 14 -16 hours daily. A medium-sized exporter with two-

threeweaving mills under him and one two dyeing plants needs to install a generator per

unit. Thisbrings the number of generators to five -six generators on an average. The cost of

running thegenerator per h our comes to eighty rupees (inclusive of all costs, maintenance

etc.). Therefore, per hour the cost multiplies to INR 320 INR 400 (approximately)]. This

when multiplied with the total number of hours a generator works in a month at the

exporters place comes to a huge amount. The dismal state of electricity is not new, this has

been the situation since the beginning.Staying without electricity has become a part of lifefor these exporters of Bhadohi who makes a substantial contribution to Indias export

revenues. However, Panipat has a better power situation than Bhadohi. This can be pa rtly

attributed to the close proximity that Panipat has with the national capital New Delhi. The

Government approved Bhadohi as a special economic zone in the Exim Policy 2002 -07.

However, any development as expected in a SEZ is still far off.

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Main Market:

y Latin America

y South America

y US

y Japan

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Hand knotted woolen othes

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Source: Discussion with Industry Experts

Argentina0%

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Belgium0% Brazil

0%Canada

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Germany

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U.S.A.

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U.K.

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Others

8%

Chart Title

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0

200

400

600

800

1000

1200

1400

1600

1800

2000

2005-06 2006-07 2007-08 2008-09

Country

Argentina

Australia

Austria

Belgium

Brazil

Canada

Denmark

Finland

France

Germany

Italy

Japan

Netherlands

Norway

Sweden

Switzerland

Spain

U.S.A.

U.K.

Others