Compliant Carpet Factories From Around The World: Start Manufacturing today!

Interior decoration has a lot of scope nowadays. Everyone wants to beautify their living spaces according to their lifestyle and preferences. 

People are always looking for options that would turn their living space into a piece of art without much effort. The easiest and affordable way to do it is by adding an eye-catching carpet.

Carpets are floor coverings made out of textiles. Also described as rugs, carpets cover a much larger area than typical floor mats. They are generally made of wool, cotton, linen, or synthetic fibers like polyester. 

Carpets have been around since nomadic times. People used to cover their tent floors with grass, animal skin, and, later on, woven reed. When fibers like cotton and jute were discovered, rugs out of these materials replaced the earlier ones. 

It was the Egyptians around 3000 BC that used pieces of woven wool material sewn together to cover their floors. This gave birth to the modern carpets that are used so extensively today. 

The traditional carpet-making process was quite laborious. Carpets were hand sewed with materials like cotton, wool, or hemp. Countries like Iran, Turkey, China, and India dominated the carpet industry for centuries before the Europeans and Americans industrialized the process of carpet making. 

Today, The United States accounts for 45% of the total carpets manufactured in the world, with the highest concentration on carpet factories.  

The simplicity and the versatility of the carpets have kept their demand steady in both developing and developed nations. This is the reason why the global carpet industry is growing by leaps and bounds every year. 

Here are 3 top carpet factories in the world-

1. Mohawk Industries, USA-

One of the top names when it comes to carpet factories, Mohawk Industries, is based out of the United States and came into existence in 1878. They manufacture a variety of flooring products but are essentially known for their exquisitely designed carpets. Their accent rugs are always in demand. But what makes this brand unique is that they make their carpets with a stain protector that is extremely child/ pet friendly. They also provide a lifetime warranty with all their products. 

2. Associated Weavers, Belgian-

It is one of the largest producers of tufted handloom carpets in Europe. This brand is known for its pocket-friendly carpets. They offer a variety of carpets of different materials and colors that are extremely affordable. Their tagline "Carpet your life" is a brilliant marketing strategy that has been successful in attracting middle-income households to their products.

3. Shaw industries, USA-

Another major name in the world of carpets, Shaw industries, is one of the largest carpets manufacturers in the world. Based out of Dalton, Georgia, their carpets are known to be exceptionally durable. But it is their sustainability program that makes this brand stand out. They have established a recycling network where they recycle old carpets to manufacture newer ones. They are also known to special-treat their carpets to be dust and water-resistant, making them last longer.

The step-by-step production process of carpets- 

As more and more people are getting conscious about their living spaces, the demand for carpets is only predicted to rise in the future. This makes carpet manufacturing a very lucrative business opportunity. 

Given below is the step-by-step process of the manufacturing process of carpets. 

There are three ways of making carpets- Woven, tufted, and bonded.

• Woven carpets are traditionally made where the fibers are interwoven into a backing. This is a longer process, thereby expensive.

• Bonded carpets are the easiest to manufacture, but the end products are not very durable and long-lasting. Here, two ready-made layers, the fibrous top part and the pre-woven backing are heat infused and bonded together.

• Tufted carpets are the most common types of carpets available in the market. They can be easily manufactured and extremely durable. This process involves stitching the fibers into a pre-woven backing with multi needles machines. These fibers are secured with heavy latex, making the carpet durable.

Here is how Tufted carpets are manufactured in carpet factories-

1. Sorting the wool-

Wool is the most commonly used fiber because of its amazing qualities. It is a renewable resource that is extremely resilient to foot pressure. Wool can bounce back even after being under constant pressure. It is also resistant to combustion and anti-static. Carpets made with a combination of wool and sisal are soft and extremely durable.

The sourced wool is washed to free it from dirt, dust, and a sticky, waxy material called suint. It is then sun-dried for days and then sorted, where only fine fibers move to the next stage.

2. Wool carding and spinning-

The dried fibers are carded by hand or using carding brush or rollers. The carded wool is then spun into yarn using a spinning wheel. The yarn spun may be thick or thin based on the carpets to be manufactured. Usually, a 3 ply yarn is used to manufacture carpets.

3. Yarn dyeing-

At this stage, the yarn is given a color based on the carpet design. Chemical dyes containing harmful substances like AZOs are banned from being used in carpet factories. The use of high-quality internationally certified dyes is encouraged. These dyes are eco-friendly and long-lasting. Many carpet factories use vegetable dyeing as a sustainable and cheaper method. After the dyeing process, the fibers are sun-dried for 3 days, depending on the weather.

4. Carpet knitting of tufting-

This is where the fibers start to take the shape of carpets. The dyed fabric is tufted into a woven base by multi-needle machines. This is then glued together to make it sturdy. The loops are then cut, and the carpets are ready for the next step.

5. Washing the carpets-

The tufted carpets are now ready to be washed with chemicals to remove the dirt and dust collected during the tufting process. One final wash is given to add a layer of shine to the carpet. These are then dried, either in the sun or drying machines, depending on the humidity of the place. 

6. Shearing and Side binding- 

The dried carpets are sheared to give them a smooth touch. The final design of the carpet finally comes to life with all the brilliant colors in full display. The carpets are also bound by a thick thread around the edges to give them additional strength.

7. Stretching-

The carpets are attached to metal frames and hung. Tufted carpets have rolled sides and edges, and stretching helps them get them into the desired length and shape. The carpets are hung like this for 2-3 days.

8. Finishing-

The carpets are given trims to remove excess materials. Checks are conducted at this stage to overlook the final design of the product. This completes the manufacturing process.

The finished products are then packaged carefully and stored.

Start your carpets business today with Fashinza-

Want to start a lucrative carpet business but don't know where to start? Fashinza can help you. 

We at Fashinza are an online B2B platform that offers end-to-end solutions for all your manufacturing needs. We work with a global team of manufacturers and suppliers to provide you with market-ready products. Every process, right from sourcing materials to manufacturing to quality checks will be done by us. You can choose from an extensive array of carpet catalogs and launch your very own carpet business within 40-60 days. 

So, connect with us to open up great business opportunities and make us part of your growth journey!