Carpet manufacturing technology
They make carpets from yarn, which can be woolen and synthetic. Of course, carpets made of 100% wool have a great price. Among synthetic yarns, polypropylene, improved polypropylene (Het-set), and acrylic are used.
There are three manufacturing techniques for carpets, which differ in the way the yarn is fixed on the basis of: tufted (needle-sewn), needle-punched and woven.
With the woven method, initially whole carpets are obtained; it is closest to the manual manufacturing method. The machine is like a sewing machine with a lot of threads and needles. Baboons with threads put on over the vaults: one color - one vault. A clear order is needed to perform different patterns. First, a cotton base is woven, consisting of weaves of various threads with a weft. Next, nodules are woven on the basis - they will make a pile of carpet. Pile trimmed. For strength, latex is applied to the back of the carpet with a roller, the fabric is cut lengthwise and sent to the drying chamber. The canvas is dried and cut into carpets, and the edges are covered with an overlock, where fishing line is passed with a thread. After that, the finished carpet can be cut to get a relief pattern.
The principle of the taftinog method is flashing woven or non-woven warp with pile threads. In a special machine there is a huge number of needles and hooks located close to each other. The needle pulls the thread through the base, and the hook captures the thread and forms a loop. On the hooks is a blade that cuts each loop, as a result, on the wrong side of the carpet, a looped sheared pile is obtained. With this method, it is quite easy to vary the height of the pile and other parameters of the carpets.
With needle-punched technique, special needles without ears are used. They have notches along the entire length. First, cobwebs are formed from pieces of fibers that are superimposed on each other and placed between two plates in which many holes are located. Needles pierce through the material, grabbing the fibers and dragging them through the canvas. Between 800 and 1, 200 strokes per square inch are produced. This method is the simplest and cheapest, but the quality of carpets made with needle-punched technique leaves much to be desired.
Carpets made by the woven method have the highest price due to the complexity of the process, its strength and long shelf life.
There are also carpets made by hand, but they have a fairly high price (25-35 $ thousand) and are not in great demand.
Color the carpet in different ways:
the fiber is immersed in a container of paint;
the pattern is printed on the carpet;
the fiber is dyed during production.
The best way is the last way: with such a color, the drawing lasts a long time and does not fade.
The best option for making quality carpets would be the following: buying multi-colored woolen or semi-woolen yarn and making carpets using the woven or tufted method.
Packed rugs should be stored in a dry, ventilated area. Unacceptable mechanical effects and exposure to sunlight. They should be placed on the stand and racks at least 20 cm from the floor. Pack bales of carpets in a non-woven container cloth or plastic film.
Room and staff
For the production of carpets you will need a room with an area of 500 sq.m., in which, in addition to the workshop, there should be a warehouse for raw materials and finished products, a bathroom, a convenient entrance. About 10 people should be hired for equipment maintenance: several operators, a technologist, a manager. You will also need a designer who will develop patterns for carpets.
The carpet loom is the main machine for production. Its cost varies depending on the parameters, country of manufacture and novelty. A used machine can be purchased for 1.5 - 3 million rubles. New high-quality equipment will cost 10-12 million. Such a machine can produce up to 250 meters of carpet in 8 hours. In addition to the loom, you will need to buy a coating machine for applying latex and a drying chamber (60 thousand to 500 thousand rubles). The cost of latex is about 140 rubles per liter.
Polypropylene yarn costs about 60-70 rubles per kilogram. Cotton yarn from about 90 rudders per kilogram. Mixed yarn (acrylic and wool) from 180 rubles. The length of the thread in 100 grams of thick yarn is about 500 meters. It takes about 30 km of thread to make one carpet. Thus, 6 kg of yarn is spent on one carpet with a length of 1.5 meters. The cost of a half-woolen carpet will be about 1, 500 rubles. With wholesale, such a carpet will cost about 3, 000 rubles. Profitability can be 50%.
Thus, the initial investment required to open a carpet factory when purchasing new equipment will amount to about 15 million rubles. With active sales, the business will pay off in about a year.
To sell goods, it is better to open a website for the wholesale and retail sale of carpets. To attract customers should advertise in various publications on design, interior, needlework, conduct sales and make discounts. Using the capabilities of the designer, you can make carpets with patterns to order.
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