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Carpet Tile Production

April 13th, 2022

Carpet tiles sales have increased since their appearance on the market but have you purchased a set of brand new or reclaimed carpet tiles that did not stand up to your expectations? Knowing the basics of the production of carpet tiles is worth the time and effort because it can help you understand the type and quality of carpet tile that you are purchasing. This means that you are in a better position to know if the tile that you are about to purchase is really what you want and if it is good value for money. Take note that carpet tiles do differ in quality;some are easier to clean and maintain while others are more durable to wear and tear. This article provides you with an overview of the materials and production of carpet tiles to better equip you when choosing one for your project.

Every carpet tile starts with the type of fibre used. Traditionally, the fibres are made of nylon, polypropylene, polyester, acrylic, wool, or recycled products like PET that come from plastic bottles. Synthetic fibres are more resistant to abrasion, stain, and moisture while natural or wool fibres are easily cleaned and age more beautifully. These fibres are machine-weaved or tufted into a primary backing material that is usually made of woven polypropylene. Good quality carpets are those with closely stitched and highly dense fibres.

Do you want to check if the tile you want to purchase has good quality weaving? Simply bend a corner of the tile backwards. If you hardly see the primary backing then that is a good quality tile while seeing the primary backing as soon as the tile is bent backwards indicates poor quality weaving. The height of the fibre from the backing, known as pile height, also affects the quality of the carpet where those with shorter pile height have higher durability than those with long pile height.

The next part of the carpet making process is dye application. There are two ways that dye is applied. One is dye application before weaving and the other is dye application after weaving. Dye applied before weaving results in a more consistent and uniform fibre colour while dye applied after weaving allows the manufacturer to produce different designs to make the carpet tile more appealing.

The final part of the process is called finishing. This involves the application of latex onto the primary backing and the secondary backing (usually made of a synthetic polypropylene material). The tile is then heated and pressed to make sure that the primary and secondary backing firmly adhere to each other.