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How is Modern Carpet Created?

By Aladdin Modjarrad

Just how are today’s carpets actually created? You have probably never even given that question too much thought but the process that sees thousands of individual fibers into a beautiful floor covering is actually quite fascinating. While it may not be the most exciting topic of conversation for your next social gathering it may help you to keep the information in your mind when you are shopping for new carpets.

Most modern carpets begin life as a collection of loose strands that are known in the trade as staples. Staples are added to a hopper, where they are subjected to intense heat, lubrication is added and the staples are formed into slivers, which are wound onto huge spools. At this point the real business of carpet making can begin.

Most modern carpets are created by following a manufacturing method that was dreamt up many decades ago in Dalton, Georgia, which is considered to be the unofficial carpet capital of the world. The process is called tufting. Tufting begins when a needle is used to push each individual sliver through the carpet backing.A hook called a looper hook holds them in place as the needle enters the backing again to form a loop. When tufting was invented all of this work was performed by humans, a tedious business indeed one imagines. These days robots are on the job and robots don’t bore easily.

If the carpeting being created has been designed to be one of the tufted variety this is where the process ends.If it is going to be a cut pile carpet though, it still has be passed over a whirring set of knives, held in place once again by those loopers.

Color is added at one of several stages of carpet production.A process called the Beck process involves the whole finished carpet being plunged into vats of boiling water and the dye is gradually introduced.

Continuous dyeing on the other hand is the process of spraying and rolling dyes onto the finished carpeting while pre dyeing colors the yarn itself, before it ever becomes anything vaguely resembling a carpet, which often creates the most uniform color.

The last steps see the finished carpet washed again and then vacuumed when dry. As a final quality check humans look the finished product over to make sure that all of pile is consistent and uniform. If the carpet passes inspection it is wrapped up and then begins its journey to the showroom or store, destined to eventually brighten up homes and offices all over the world.

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categories: carpeting,flooring,flooring options,choosing carpets,carpet,carpets,carpeting,interior design,flooring,flooring options,home decor,home renovation,remodeling

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Article Citation
MLA Style Citation:
Modjarrad, Aladdin "How is Modern Carpet Created?." How is Modern Carpet Created?. 21 Jun. 2010. 5 Oct 2014 <>.

APA Style Citation:
Modjarrad, A (2010, June 21). How is Modern Carpet Created?. Retrieved October 5, 2014, from

Chicago Style Citation:
Modjarrad, Aladdin "How is Modern Carpet Created?"

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