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production process

01

Tufting: the yarn

BCF yarn:
2 types: PA 6 – PA 6.6.

02

Tufting on PES non-woven
primary backing.

  • superior dimensional stability;
  • temperature durability is extreme.

03

Tufting

Perfect seams,
in all products.

04

Tufting: Loop pile


05

Tufting: Cut pile


06

Dyeing: Solution dyed

= Colour pigments are added to the different filaments before they are extruded into yarn.

+ The filaments are dyed through and through so that there are no visible colour differences and seams between the different tiles.
+ Better colourfastness.
- Large production runs.

Example: Millennium, Centennium.

07

Dyeing: Space Dyed

= Several colours are printed onto the yarn, thus creating
specific colour combinations.

+ Gives a special effect to the carpet.
- The colour pigments do not penetrate as deeply into
the yarn.

Example: Resist100, Reverse100.

08

Dyeing: Piece Dyed

Result:

  • Unicoloured = even dyeing.
  • Differential dyeing = multi-coloured dyeing.
  • The result depends on the chemical composition of the yarn.

09

Latex

Purpose

  • Anchoring of the pile.
  • Assure dimensional stability.
  • Improve backside.
  • Resistance to fraying.

Steady amount of latex = uniform thickness.

10

Latex: oven

A long oven

  • Low temperature.
  • Better pile bonding.

11

Latex: control


12

Bitumen line

13

Bitumen

The purpose of the backing is to:

  • anchor the pile;
  • improve the dimensional stability;
  • give weight to the carpet tile;
  • enhance the feeling of comfort.

Working with extrusion gives a constant
coating composition.

14

Antistatic

An antistatic agent is a compound used for treatment of materials in order to reduce or eliminate buildup of static electricity

15

Tile markings

Each carpet tile is printed with
the following information.

  • arrow: indication of the production
    direction;
  • batch number;
  • SAP-number;
  • date and time;

16

Plates


17

Cutting of the tiles

All products have a perfect connection of the seams.

18

Cutting of the tiles: control


19

Packaging

1 box contains 5 sqm carpet tiles.

20

Expedition

1 pallet contains 20 boxes (100 sqm).

21

Storage

  • Smooth stock rotation.
  • Good production times.

...