When it comes to softness and comfort underfoot, shaggy carpets are one of the popular choices which add warmth and cosiness to living spaces. These are a type of flooring or rug characterised by their long, fluffy pile of fibres that create a plush and luxurious texture. In this blog, we will discuss how Shaggy Carpet Manufacturer India manufactures these beautiful floor coverings with a step-by-step guide.
Material Selection
Choosing the right materials is an initial step in manufacturing shaggy carpets. Top-notch Shaggy carpet manufacturer in India like Genie uses synthetic fibers like polyester, nylon, or a blend of these materials. These are known for their durability, ease of maintenance, and affordability. The choice of material also determines the carpet’s colour and texture.
Fiber Extrusion
Once the materials are finalised, they pass through a special process called fibre extrusion. In this process, the selected synthetic fibres are melted and forced through tiny openings to manufacture long, continuous strands. These strands are cut to the length to form the shaggy fibres.
Spinning and Twisting Step
The extruded fibres are then spun by artisans of Genie shaggy carpet manufacturer India into yarns and twisted together to give strength and resilience to the piece of decor. This spinning and twisting process also helps in creating the characteristic texture of shaggy carpets. The tighter the twist, the more defined the shaggy texture will be.
Dyeing for Desired Colors
Before moving to the next step, the yarns are dyed to get the expected colours. Shaggy carpet manufacturer in India, like Genie, uses specialised dyeing techniques to ensure uniform colour distribution throughout the carpet. It is considered an imperative step to create vibrant and long-lasting carpets.
Tufting
In the next step, tufting is used to insert the twisted and dyed yarns into a backing material to form the carpet’s pile. When it comes to manufacturing shaggy carpets, Genie Shaggy Carpet Manufacturer India adjusts the tufting machine to create longer loops of yarns. It will be used to cut the form of the characteristic shaggy texture. The backing material in the shaggy carpets holds the tufted yarns in place and adds stability to the carpet.
Shag Formation
After tufting, the carpet is passed through a cutting machine equipped with specialised blades that trim the yarn loops to the desired length. This cutting process is what creates the shaggy texture, giving the carpet its distinctive look and feel. The length of the shag can vary, allowing manufacturers to create different styles of shaggy carpets, from short and plush to long and dramatic.
Secondary Backing
To enhance the carpet’s durability and stability, a secondary backing material is applied. This backing is typically made of latex or other synthetic materials and is bonded to the primary backing, securing the tufted yarns in place.
Quality Control
Quality control is a crucial step of the manufacturing process, including careful inspection of each carpet to ensure it meets their quality standards. Genie Shaggy Carpet Manufacturer India checks for any defects, ensuring uniformity in colour texture and verifying that the carpet meets the specified dimensions.
Finishing
It is also considered an important step to check out the finishing process, including trimming any loose fibres and applying a protective treatment to resist stains and soiling. This step ensures the carpet’s lifespan and makes it easier to clean and maintain.
The End Note
Overall, the manufacturing process of shaggy carpets is a perfect combination of technology, artistry, and craftsmanship. From finalising the materials to the finishing touches, Genie shaggy carpet manufacturer India gives extra attention to manufacturing these mesmerising and luxurious floor coverings. Understanding the step-by-step process of these soft floor coverings can be an interesting topic for you. You can appreciate the skills and efforts that go into producing these beloved home décor items. Whether you want to know the efforts behind these carpets or market new trends, this guide will help you fulfil your curiosity.