Process

NAYYER CARPETS IS THE SOLE PAKISTANI COMPANY WHICH SPECIALISES IN THE PRODUCTION AND MANUFACTURING OF SYNTHETIC YARN CARPETS, USING THE LATEST MACHINERY AND EQUIPMENT TO ACHIEVE SUPERIOR RESULTS.
THERE ARE THREE TYPES OF ARTIFICIAL YARN WHICH ARE PRODUCED

  1. NYLON CARPETS
  2. POLYESTER CARPETS
  3. POLYPROPLYN CARPETS

THE PROCESS
1. FIRST THE YARN IS MADE OF REQUIRED MATERIAL

  • NYLON YARN
  • POLYESTER YARN
  • POLYPROPLYN YARN
THESE 3 TYPES ARE SPLIT INTO 3 SUBCATEGORIES EACH
  • BCF YARN (NON TWISTED)
  • HEAT SET YARN (NON TWISTED)
  • HEAT SET TWISTED YARN

2. NOW, AFTER THE YARN IS MADE, IT IS PLACED IN THE TUFTING MACHINE, IN WHICH THOUSANDS OF NEEDLES ARE THREADED WITH SEPARATE ROLLS OF YARN EACH. THIS MACHINE ROLLS A PRIMARY BACKING CLOTH THROUGH, WHILST TUFTING IT WITH EITHER LOOP OR SINGLE STITCHES, DEPENDING ON THE SPECIFICATIONS OF THE CARPET. THE NEEDLE PUNCHES THROUGH THE PRIMARY BACKING AND IS CUT AT THE BOTTOM FOR A CLEAN FINISH. THERE ARE TWO TYPES OF FINISHES / PILES, WHICH CAN BE PROGRAMMED TO BE CREATED ON THIS MACHINE

  • CUT PILE, EACH STITCH IS CUT THROUGH THE MIDDLE TO CREATE SINGLE THREADS
  • LOOP PILE, EACH STITCH IS KEPT WHOLE, WHICH MAY RESEMBLE A STITCH ON A SEWING MACHINE
AT THE END OF THIS PROCESS, THE SOON TO BE CARPET NOW RESEMBLES A TOWEL. THIS IS USUALLY IN TWO COLORS a) WHITE, WHEN USING NYLON YARN b) COLORED, WHEN USING POLYPROPRENE COLORED YARN, WHICH IS USUALLY KEPT PLAIN

3.A WHITE CARPET IS THEN USUALLY PUT THROUGH A PRINTING MACHINE, WHERE THE CHOSEN DESIGN IS APPLIED. THIS DESIGN IS MADE WITH THE LATEST TECHNOLOGY, HANDLED BY DESIGNATED GRAPHIC DESIGNERS, THEN ONCE THE DESIGN IS FINALISED, COLOR SCHEMES ARE SELECTED

4.THE COMPUTER IS THEN ATTACHED TO A SMALLER PRINTING MACHINE, WHICH CREATES A SAMPLE, GIVING THE DESIGNERS AN IDEA OF WHAT THE FINAL PRODUCT WILL LOOK LIKE, AND IS TESTED TO SEE IF IT FITS THE STANDARDS THAT NAYYER INDUSTRIES FOLLOWS.

5. WHEN APPROVED, IT IS MANUFACTURED ON A BIGGER PRINTING MACHINE, WHICH PRINTS MILLIONS OF SQUARE FEET OF THE DESIGNATED DESIGN ONTO CARPET

6. NOW AT THIS STAGE, THE CARPET IS BACKED WITH AN IMPORTED GLUE SUBSTANCE, WHICH IS THEN ATTACHED TO A SECONDARY BACKING NET.

7. THEY ARE THEN FED THROUGH A ROLLER, WHICH PRESSES THE CARPET AND BACKING TOGETHER AS WELL AS RIDDING OF EXCESS GLUE. AS THE MACHINE ROLLS OUT THE PRESSED CARPET, IT IS FED THROUGH A HEATER TO DRY THE PRODUCT, NOW IN THE FORM OF A CARPET.

8. TO FINISH, THE CARPET IS ROLLED THROUGH ITS FINAL MACHINE, WHICH TRIMS ROUGH AND FRAYED EDGES, ROLLING THE FINISHED CARPET INTO ROLLS OF THE REQUIRED SIZE.

9. IT IS THEN STORED IN A WAREHOUSE READY FOR SHIPPING