Manufacturing

Having control over the whole manufacturing process, from tufting to backing, means we can carefully monitor the quality of our products and our environmental impact.

Our manufacturing history is underpinned by continued research and development. This enables us to deliver carpets that achieve the highest standards in performance, but more importantly for you as the customer, advancement in yarn and manufacturing technologies that result in a superior flooring finish.

This section will take you through our manufacturing processes looking at the yarns we select to produce our carpets, including the ECONYL® yarn which is 100% regenerated and infinitely regenerable. The processes of tufting, tip shearing and backing. Plus the steps we take to ensure all quality standards have been met.

 

Highest Quality Yarn

Carpet fibres, which are manufactured into yarn, play an important part in determining the quality of a carpet. The yarn directly influences many aspects such as surface structure, colour and feel as well as the functional benefits including resilience to wear, colour fastness and soil and stain resistance.

At danfloor we carefully source our yarn so that our carpets have excellent performance characteristics which ultimately increase the product lifecycle.

We ensure that the yarns are selected from well-known and branded suppliers who can maintain consistency of output and quality.

By looking at the intended use of the carpet we can determine which yarn will be most suited to that carpet and its application, which ensures you receive a flooring solution that is fit for your purpose.

Tufting

Tufts are clusters of yarn that are drawn through a base layer. The needles of the tufting machine push the yarn through the base material. Settings on the machine can be programmed to create pile tufts that are uniform in height and distribution. The machine can also create a pattern composed of tufts of different lengths.

Here are some interesting facts about the danfloor tufting process which takes place in our Danish manufacturing plant:

  • To produce 25 linear meters by 4-metre wide roll of carpet requires 1273 cones of yarn which are known as creels
  • To set up a brand new carpet production takes 1 person 6-7 hours to “creel” a machine
  • 1273 needles, which are similar to sewing needles, are used to produce a 25 liner metre by 4-metre wide roll of carpet
  • It takes just 15 minutes to tuft one role of carpet
  • In excess of 2,000,000 square meters of carpet can be produced a year at our manufacturing plant
  • At the end of this process, the creels are stripped of any remaining yarn which is then melted down and used to create new yarn.

Tip Shearing and backing

Once the carpets have been tufted they are then transported to our backing facility to go through the finishing processes.

Firstly the carpets are brushed and lightly sheared to remove excess fibres and to obtain a uniform height. To achieve this, the carpet passes through a machine with a cutting cylinder that resembles a lawnmower. The blades of this machine are adjusted so that they barely touch the surface of the carpet yet are able to remove loose fibres which are then suctioned from the surface.

The carpets are then checked for any imperfections, which are fixed immediately, and then receive another brushing and shearing which assists with the bursting of the pile during the steaming stage. Our carpets are steamed to help the pile plump up and become softer.

During the manufacturing process, the tufts are loosely sewn into the backing fabric therefore it is necessary to back-coat the carpet. Many of danfloor’s backings are impervious and also remove the need for an underlay.

Once the carpets are finished they are rolled onto plastic tubes which are also made at our backing plant. The tubes are produced from small bits of recycled plastic which are melted down and then cooled into tubes.

Quality Control

Throughout the manufacturing process, from receiving the yarn to the final finished product, each process is subject to strict quality control procedures. A final inspection is then undertaken prior to dispatch to ensure you receive the quality carpet you are expecting.