Basic Science of Hospitality
Carpet
Templeton's carpets featured in this website have been designed
primarily for Hospitality applications. We manufacture our products for
performance by tufting dense constructions utilizing state of the art
equipment and by using superior durable yarns. Most of our products are
tufted from our 1/10 gauge broadloom tufting machines using continuous
filament solution dyed nylon yarns and are finished with ActionBac®
secondary backing.
For your information, the machine gauge refers to the number of needles
in each inch across the width of a tufting machine. 1/10 gauge machines
create very dense carpet utilizing 10 needles per inch (1/10). There are
1440 needles across 12 foot width carpet or 1800 across 15 foot width.
Each needle carries one end of yarn. The coloration and pattern for the
carpet is created by threading different colors of yarns into specific
needles and then by moving these needles from left to right
intermittently via computer driven design mechanisms. The needles tuft
(or punch) a loop of yarn thru a synthetic woven "primary" backing.
These loops are tufted continuously as this backing is unrolled and fed
through the tufting machine. In this continuous movement, "stitches" of
yarn are tufted down the length of the carpet. With a 1/10 gauge machine
and 10 tufts per inch across the width, you can easily then have 12
tufted stitches or more down the length. Using this example, you have
120 tufts (10 x 12) in a square inch of tufted carpet, creating superior
density. The individual tufted loops are either cut to create a cut pile
carpet or pulled tight to create a loop pile, depending on the desired
texture. This all happens at an average rate of 50-100 feet per hour.
Hundreds of lineal feet of carpet are tufted in one process creating
large rolls called greige. They are called greige goods because the
tufted carpet is a flexible unfinished cloth at this point.
Again for durability, the majority of our products are tufted using continuous
filament solution dyed nylon yarns. Solution dyed means the yarn color
is an integral part of the fiber, that the color is included during the
melted raw yarn extrusion process. This is a different process from
"piece dyeing" as used in most residential cut pile products.
Conventional piece dyeing is performed in becks or continuous dye ranges
where color is added to dye baths holding "white" tufted carpet. For a
better idea of the significance of solution dyeing and as and analogy,
picture the color consistency of a carrot versus a red apple. Cut though
a carrot and you have the same vivid orange color all the way through
the cutting. This is how a solution dyed fiber looks when you cut though
the fiber. But when you cut through a red apple, you only have color on
the outside surface, and that is how color shows when you cut through a
"piece" dyed carpet fiber. So back to solution dyeing, the color
therefore is a permanent part of the fiber (same as the carrot cutting)
and has superior colorfastness and resistance to stains and chemicals
over conventional or piece dyeing processes.
In order to finish the tufted carpet, we must lock in the tufts and
provide stability to the tufted greige roll. To do this we apply wet
glue-like latex to the back of the primary and add a secondary synthetic
backing called ActionBac®. This process is through a finishing oven that
is often referred to as a coater. The wet latex is applied
simultaneously to a second layer of ActionBac® backing and to the
original greige/tufted primary backing. These two backings are then
pressed and bonded together and the latex is cured as the carpet travels
through the hot oven/coater. The carpet is a finished product as it
comes out of the oven and it is then cut into shippable roll sizes.
Please call us for your Commercial/Hospitality Carpet Needs -
1-800-481-9163!
For a certified carpet installer in your area click here
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