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 uniformed height. To achieve this, the carpet passes through a machine with a cutting cylinder which resembles a lawn mower. 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.