In carpet frame TC cotton are arranged into warp
direction.
Hand knotting actually done in TC yarn by wool
yarn.
Pile height depends on the carpet design and
types.
Knotting depends on the carpet length and
height.
The knotting by the worker hand.
Every warp yarn insert in to heald eye.
There heald shaft used to yarn the held eye.
There two sites of warp yarn used to in warp
direction.
When inside knotting finished then the heald
shaft need to turn up or down.
Then another side knotting has to be done.
In above way knotting and backing of carpet can
be produced.
Shearing and Trimming:
Objective of Shearing and Trimming:
To equal the pile height carpet.
To remove extra knotted pile from carpet.
Procedure:
First have today down the carpet
Then have to cut the extra pile by knife.
Then have to wash the extra pile from the
surface of carpet.
Final Touch and Finishing:
Objective:
To improve the quality of carpet.
To sew the backing of carpet.
To suitable for market.
Procedure:
First we have to cheek the pile height of carpet.
Then we have to equal the pile height by using scissor.
Then final have final inspection the carpet quality of carpet.
Senior Project program send us to the expected destiny of
practical life. The completion of project work at, we have got the impression
that the factories are the Carpet manufacturing
in Bangladesh. Though it was established
from a long time, it has earned very good reputation for its best performance
in Bangladesh Market.
During our senior project program we had tried to our best to done our duty. It is completely a new experience in our life. Although we had some barrier during project, but lastly we recover it and which will be very effective in our service life. During our project period we realized that practical experience is valuable for service life.
First of all the authors express our gratitude to supreme
Allah for blessings, approval, protection, mental power and wisdom in all
aspects of our life. The applauses to Allah to complete this project work. This
work has been carried out at different carpet factory, Department of Textile
Engineering, City University. During the thesis work, many individuals have
unselfishly contributed their time, support to make this project possible. We
would like to extend our sincere gratitude to those who have provided guidance
in every step along the way.
The authors deeply indebted to our honorable supervisor Lecturer,
Department of Textile Engineering, City University. Our honorable supervisor encouragement
helped us in all the time of research for this thesis. Her scientific
curiosity, encouragement and guidance throughout this work have been necessary
for this thesis. She helped us every moment during this Project. Without her
help it was quite impossible to do this project.
The Peter Zimmer machine operates on the principal of the electro magnetic double roller squeegee. The print paste confined between two rollers which are of a considerably larger diameter (80 mm). Pile penetration by the print paste is achieved by pressure wedge of paste trapped in front of the second roller as it moves forward over the screen. In this machine screens are covered with 60-70 mesh polyester screen fabric. The downward pressure and reciprocating motion of the squeegee roller is achieved by a bank of electromagnetic moving beneath the endless rubber belt that carries the carpet. Maximum running speed is usually 2-4 m/ min, depending on carpet quality.
Principle
The
UV screening agent is applied in combination with TERASIL X dyes by flat screen
direct printing.
The
light fastness improvement achieved for
two dye combinations is assessed colorimetrically by standardized HT light
exposure tests.
Procedure
Material
Tersuisse
polyester tricot,
washed off, heat
set at 175°C
type
2031 (No. 5-4204 )
Machinery
/ apparatus
Zimmer
Mini MDF 305 flat screen printing machine drying oven
Mathis
high temperature steamer
Dyes
Dyes
beige
charcoal
TERASIL
Yellow X-GWL
1.3
g/kg
TERASIL
Red X-GSA
0.3
g/kg
TERASIL
Violet X-B
0.04
g/kg
TERASIL
Blue X-BGE
0.3
g/kg
TERASIL
Grey X-SGN
50 g/kg
Stock
thickening
120 g
Solvitose C5 10 %
480
g Lamitex M5 6 %
380
g de-ionized water
5 g sodium dihydrogen phosphate
10
g sodium chlorate 1:2
5 g LYOPRINT AP
1’000 g
The carpet is transported by means of an endless rubber blanket or rubber strips. It is sometimes carries small pins on the surface to grip the
Four type of rotary screen printer for carpets have been produced namely.
The Peter Zimmer machine with a magnetic roller squeegee friction driven with variable magnetic pressure.
The Peter Zimmer Hydroslot system which relies on hydrostatic pressure to force the paste through a slot in the special squeegee box and into the carpet pile.
The Mitter positively driven roller squeegee which combines the use of large squeegee diameter and high paste levels be hind the roller to achieve good color penetration into the carpet pile. Special flexible screens of triangular cross section can give repeats up to 4 meter.
The Johannes Zimmer Magnojet and Viriojet machine which are a further development of the Hydroslot system.
Tapestry Carpet :
Tapestry Carpet also a handmade carpet. Here wool&
cotton is used. Any kind of design can be done on the surface of Carpet. Human
being, animals, natural beauty, Birds, etc design cane be done this type of
Carpet. Pile height depends on the design object of carpet.
The Fardin Carept is one of the carpets known carpet associations
in Bangladesh. They have different kind show room in Bangladesh. They actually
collect the carpet from Millat Camp.
In Millat
Camp, the Bihari People only made the carpet . They also export the carpet in
Malaysia. Only 4 looms they used.
In
Bangladesh there was another Carpet Manufacture that is “Bengal carpet Ltd.”.
Actually they were the main Carpet manufacturer in Bangladesh. They were stared
a new sensation on carpet manufacturing in Bangladesh and abroad also. Bengal
Carpet was started there journey in 1980.They also exported their in Italy,
Franc, Germany, etc. They made their carpet by Machine loom. They could make
twist , velvet portion carpet ,mat, hang mates. But now they are stopped their
carpet manufacturing. Because the lack of order. They started carpet
manufacturing in a benefits way but day by day they faced in loss of
production. For this reason they stopped their production.
They
stopped their production in 2002.
But now
days they are making mat, braided lace and
But now days they are making mat,
braided lace, and jute rope etc. Now they are thinking to sell their industry.
Another man
who sustain carpet manufacturing in Bangladesh. He is Ali akbor the owner of
“Society handicraft”. He stared his mission from1988. But he organized his
organization from 1990. In 1990 he started his organization with 1 loom. But
now it is standing in 60 looms. Per month he earned 6 to 7 lac taka.
Mainly “Aarrong” is the main suppliers of his organization. Aarrong give
him design and according to their design
Ali akbor make carpet. Ali akbor is a very skill man who can make any kind of design on his carpet.
Society handicraft mainly situated at Nana Genda, in Savar.
Now a day Society Handicrafts played a vital role on Carpet market in Bangladesh.On the other hand in Rangpur district there have some Carpet manufacturer. They also made Carpet, Sotoronji, etc.
Moreover our well known stair carpet runners and carpet
runners collection (still produced in France in one of the only remaining and
genuine Aubusson carpets factory) is now purchased from all over the world and
shipped to thousands of customers from Europe (U.K., France, Belgium, Poland,
Romania, Spain, Switzerland etc…) or from the U.S.A, Far East, Middle East,
Africa etc… Eventually, we have also developed over the last few years a
significant volume of custom made hand tufted wool area rugs and luxurious
handmade hand tufted carpet runners and wall-to-wall carpets business in
partnership with some of the most experienced and skilled Indian and Chinese
companies.
The print head of the stalwart machine consists of up to four print rollers, which run in troughs containing a thin print paste with the caret pile to be printed being pressed against the upper surface of the print roller from behind. The print rollers are arranged at 45 to the vertical one above the other. Maximum running speed is about 6m/min.The individual print rollers consist of steel centered wooden bowl on the surface of which is mounted the design. The design is cut from thick rubber covered with a nylon or polyester pile. Read about Rotary-Screen Printing Machine
Limitation of the Stalwart machine:
As the narrowest rubber strip that can be mounted on the roller about 4 mm wide. The machine has however proved ideal for the production of the so called shadow-printed effects on the long pile carpets, which have remained in fashion for many years.
Material:
Mainly it is used yarn wool (raw material). Most of the yarn
used in ring yarn, acrylic yarn, synthetic yarn etc. These yarns are collected
from Narayangong. The yarns are buying by a lot system and this lot gets
different types and color of yarn.
To produce carpet use the frame of wood, bamboo and iron rod
etc.And also use different instrument like kamana, golla, panga (reed) etc.
They are also used some specialized yarn shanel yarn, smaglin yarn etc.
Wool Washed and Drying:
Wool is one kind of natural fiber. So, different types of
impurities involved in wool yarn. If we remove impurities the final product
will fine. So we have to washed and dry the wool.
Objective of Wool Washed and Drying:
To remove the impurities from yarn.
To remove oil y properties of yarn.
To increase soft handling properties.
To suitable for the next process carding.
Procedure:
It also done by manually. In Egypt, Malaysia, also
Bangladesh carpet manufactured by manually:
First have to mix the detergent into water at a bath.
Then drops the yarn into bath.
Stirling the yarn in to water by any stitch.
Then dry the yarn by sunlight.
Carding:
This is the process of spinning where it is functions are to
separated align and delivery the fiber in a sliver form and remove impurities.
Objective of Carding:
Opening to individual fibers.
Elimination of impurities and dust.
Elimination of impurities Short fiber.
Fiber blending.
Fiber orientation
Spinning:
The process by which convert of fiber to yarn.
Objective of Spinning of carpet:
By spinning 3,4,5,6,7,8,9 ply yarn can be produced.
Cost analysis of Carpet:
We don’t know about foreign carpet
yarn cost due to barrier of project. But we know imported carpet cost from new
markets shop. In Bangladesh there have some carpet manufacturer. We visited
Millat camp, Society handicrafts. We collected some yarn cost from them. Some
cost analysis is given below,
Yarn
Cost per kg
TC
320tk
Jute
150tk
Wool
500tk
Acrylic
370tk
Smarkling
450tk
Cost difference in Local Carpet and Imported Carpet:
Carpet
Types
Local
Carpet/sqft
Foreign
Carpet/sqft
Twist Carpet
120tk
90tk
Balika Carpet
110tk
70tk
Tapestry Carpet
130tk
100tk
Maya Design
85tk
70tk
Mozaik Design
95tk
70tk
Diamond Design
90tk
65tk
Leaf Design
110tk
90tk
Difference between properties of Foreign and Local Carpet:
Foreign Country: Belgium, Dubai, China, Malaysia, Turkey, India, Pakistan, Egypt are
the main source of Carpet in all over the world.
On the basis of countries the different type’s carpet name
are given below,
1. Egyptian carpet
2. Pakistani Carpet
3. Malaysian Carpet
4. Turkish carpet
5. Persian Carpet.
6. English Carpet
7. French Carpet
8. Chinese Carpet.
Source of yarn in Carpet raw materials in Bangladesh:
►Mirpur (From Zhut business man)
►Narayangonj
►Chak bazar, Dhaka.
►Gulistan, Dhaka.
Export and Packaging:
Object:
►To package the product.
►To dispatch to Buyer
3.4.3Pretreatment of carpet:
In front of the printing machine there are the conventional
carpet take up rolls, a space for butt sewing a j-box or compensation roller
storage unit followed by a back better and a lint extraction system.
It is not usual to give wet pretreatments to the carpet
before printing because the materials that may still be on the fiber such as
spin finishes do not in general interfere with the absorption of the print
paste or the fixation of the dyes. An exception arises with some carpet
qualities improve if they are pre washed a about 60 C BEFORE PRINTING.
This rewashing produces a bulking effect on the fiber which
can not be achieved by steaming alone although pre steaming is sometime use in
place of hot water treatment.
In some cases superior penetration is obtained on pre wetted
carpet one example is the printing of longer pile carpet. After wet
pretreatment the carpet is passed over powerful extraction slots to reduce the
residual moisture the between 50 and 80 pick up, depending on carpet quality.
Carpets may also be pre added with a ground shade for certain resists,
displacement and discharge process
3.4.4After Treatment:
No dyes can be completely fixed on carpet fibers so that
residual dye as well as the chemicals and thickening agents must be removed by
cold water alone is used in contrast to textile printing practice. Only in the
case of polyester and acrylic carpets are heated wash tanks considered. Two or
three bath preferably with countercurrent water flow is used. A typical carpet
printing range requires a wash water flow of 20-40×103 1h. To accelerate the
interchange between the liquor on the carpet and the wash water various
agitator systems have been used in addition each exit path form the liquor
should have a spray pipe and mangle squeeze or better an extraction slot. A
particularly good effect can be achieve using perforated drum wash units in
which the liquor actually passes through both the pile and the backing of the
carpet
Where heavy very shades are being produced cross staining of washed off on to pale or whit ground shades may occur. This can be avoided by passing the carpet through a mildly alkaline bath as it leaves the steamer. This also improves the wet fastness of the print as the alkali aids the removal of unfixed dye.
Carpet Manufacturing Process
Wool Sorting
Wool Wash and Drying
Carding
Spinning
Natural Dyes
Pot Dyeing
Designing and Graphing
Dyes Yarn Shorting
Hand Knotting
Washing
Wash Rug Drying
Shearing and Trimming
Final Touch and Finishing
Packing and Export
Description of Carpet Manufacturing Process Flow Chart (Hand made basis):
Wool Shorting:
Wool yarn is mainly used in carpet manufacturing. In carpet
manufacturing process yarns have to sort we know there are different grades of
yarn min together. They have different shade variation, staple length
variation, etc. For this reason we have to sort first those yarn.
Objective of Wool Sorting:
Differentiate same grade yarn.
To combined the same length yarn.
To eliminate the faults of carpet.
To helpful for next carpet manufacturing process.
Procedure:
It is a manual process .It is mainly done by hand.
From wool lot, we have to diffeintiate different kinds of
yarn according to their length color or shade and difference grade.
Then it wills suitable next process.
Carpet design in Bangladesh:
In “Society Handicrafts” different kinds of design can be
done. They can do any kind of design. Aarrong gave them swatch or design and
finally they sketch in graph paper and also make a sample of carpet. Then they
a take an approval from Aarrong and go for bulk production.
The owner of Society Handicrafts first designed a design.
Then supervisor draw design in all looms.
In Society Handicrafts design name are given below,
Design for Twist and Balika Carpet,
1. Maya design
2. Mosaic design
3. Zamdani Design
4. Zebra Design
5. Blue stripe
6. Blue shade diamond
7. Brown shape weaves design
8. Multi color design
9. Maxican Design
10. Toner step
11. Brown Step
13. Plastic design
14. Ardeko Design
15. Leaf design
Design for Tapestry Carpet:
1. Human being design
2. Boat design
3. Foreign boat design
4. Flower design
5. Elephant design
6. Peacock design
7. Kingfisher design etc
Any kinds of design can be making in Society Handicrafts.
The first establishment was originally started in Paris in
the famous “Saint Germain des Prés” area under the name of Jules
Flouron, a relative of Georges Cholleton senior who managed it after his return
from World war I, from 1919 to his death in 1956, it was then operated by his
son Pierre Cholleton (a former officer from the French free forces during World
war II and during war in French Indochina) till 1978 year of his desperation.
Over the 20th century Cholleton became one of the main
French company specialized into outside blinds, awnings and canvas as one the
very first globally specialized into blackout as flame retardant fabrics for
hotels and hospitalities curtaining.
Already in the 60’s and the 70’s Cholleton’s blackout fabrics
were specified all over Europe, including the ex SSRU, in Africa or Middle East
as for prestigious hotel contracts in the Far East.
Over a hundred years, the Cholleton Company became also one
the very first globally specialized into blackout as flame retardant fabrics
for hotels and hospitalities curtaining. It was already involved at that time
into major hotel projects all over the world, such as Hotel Cosmos Moscow in
Soviet Union, Hyatt hotel in Bangkok, Orchard Hotel in Singapore, first
Meridien Hotels in Saudi Arabia as former UTH hotels (which was the roots of
Air France Hotels group) all over Africa, Middle East and Far East as Ivory
Intercontinental hotel in Abidjan – Ivory Coast or several Hilton and Sheraton
hotels in France and abroad.
Tissues and Stores Cholleton (Cholleton Blinds and Fabrics)
was also the supplier of prestigious customers such as the French National
Assembly (French National Parliament) ,the Palace of The Elysée (Housing and
offices from the President of the French Republic), the RITZ and BRISTOL hotels
in Paris, or the NEGRESCO in Nice as numerous four and five stars hotels in
France and all over Europe.
From 1978 to 1982 the group went thought a major
reorganization following the desperation of Pierre Colleton and his son Georges
P. Colleton was the one who decided from 1982, after having met the just-new
owner at that time of Trafford carpets UK the re-orientation into the contract
carpet world and more specifically into ax Minster contract carpets for hotels
and hospitalities.
Axminster contract carpets custom made for a casino.
Today’s Agence Cholleton is still a wool carpet specialist
and the sole agent and exclusive distributor for some of the best European
residential and contract carpets manufacturers for France, several European
countries and of course the entire Middle East and North Africa, but we have
also now implemented over the last few years our own residential and contract
carpets collection worldwide distributed.
Single-end Sizing Machine4arn materials: Cotton, Polyester Cotton, Kevlar, Carbon, Glass, Jute or similar
mg materials: PVA, Starch, Wax etc.
ier of packages to be sized at a time: 1 or more Speed: 190 m / min or higher Sizing temperature range: 90-100 °C Length measuring sensor
Electrical-heating in sizing tank
Hot air drying
Yarn break sensor
Power back up for emergency shut down in safe mode Real time data acquisition / analysis system (fixed) All parts / accessories required to make machine operational on site List of similar installed machines in universities/industry in Pakistan and worldwide with their contact information.
List of trained engineers available for after sale service/maintenance keel Capacity for Sizing: 12-16 beams or Spindles
Drying System: Electrical or Steam heated with speed and temperature controlled
Size Cooker: Detachable and temperature Controlled Spare parts: 01 set
Definition and Causes: In medium to heavy weight woven fabrics, which are dyed in Jigger machines or in a continuous dyeing range, this is a very common and reoccurring problem.
Generally, the main causes are
Incomplete de-sizing of the fabric (removal of yarn’s starch),
The uneven distribution of dyes during the dyeing process.
This is due to the fluctuation and variation of the pressure in the winding and unwinding rollers.
In knit and some light weight woven fabrics which are dyed in Jet dyeing systems, this problem can rarely be seen.
This, however, occurs more in the finishing process and will be discussed in the finishing section.
Preventive Suggestions:Regular maintenance and upkeep of the dye machines will
contribute towards reducing this problem. Preparation of the greige goods prior
to the dyeing is also very important.
Corrective Measures:In most cases, stripping and removing the base color and
re-dyeing will correct the problem.
In severe cases, over-dyeing to a darker shade or black may be the only solution.
Irregular Sizing (Slashing)-
Definition and Causes: During the slashing process, in order to increase the tensile strength of the yarns and prevent breakage, starch based chemicals are applied. In some cases uneven application of the starch causes uneven surfaces in the yarn which can cause breakage and holes.
Preventive Suggestions:Correct and precise slashing is of utmost importance.
Corrective Measures:For this problem no corrective measures are available.
Yarn Breakage-
Definition and Causes: Due to the elastic nature of the Elastane-based stretch yarns, controlling the in-feed tensions of these yarns, fed individually or in plated form, is a critical part of the knitting process.
Slight increase in the applied tension will result in
breakage of the yarn particularly in finer counts (20, 30, and 40 Denier
counts).
Preventive Suggestions: Constant measurements of the tension must take place. For most structures, the tension should not exceed 4 grams.
Corrective Measures: For this problem no corrective measures are available.
Oil Stains-
Definition and Causes:
The distinctive oil stains which appear on the surface of the greige goods are normally a result of knitting machine’s needle lubrication system.
During the knitting loop formation, due to machine’s speed of revolution and the frictional forces between the yarns and the needles, a certain degree of heat is generated.
In order to prevent the elevation of this temperature, at certain pre-determined intervals the lubrication system is made to function and sprays of oil mists are applied to the needles and the cam areas.
During this process and in a lot of cases the greige goods get contaminated.
Normally, however, if the oil that is used is of the water-soluble and natural based type it can easily be removed by a simple scouring process.
In some cases, as a cost saving measure, some knitters use non-emulsified type of oil which is rather difficult to remove. These types of oil stains will appear as lighter shade spots after dyeing.
Another type of oil stains are the ones from the silicone based lubricants that are normally applied to the Spandex yarns.
In some cases, during the knitting process, and due to the generated heat some residue of this lubricant remains on the fabric. This type of oil stain is also very difficult to remove.
Preventive Suggestions:
The use of water-soluble knitting oil is strongly recommended.
Also, to the extent possible, Spandex yarns with non-silicone lubricant must be used.
Corrective Measures:
In most cases an “oil-scavenger “type of industrial detergent will be able to remove the stains.
In more severe cases a strong solution of an alkaline based chemical such as Sodium Hydroxide or Soda ash may be required.
When dealing with Spandex related stains care must be taken to ensure that the stretch and the recovery of the yarn is not adversely affected.
These are common problems with basic synthetic knit
structures such as Single jersey and Interlock, particularly when textured
filament yarns of higher filament contents are used (96 and above).The causes are basically the slippage of the fibers and the
ease with which the knitting loops can slide over each other.In most cases, these runs are directional which means that
the start of the knitting roll exhibit more runs than the end of the roll.
Preventive Suggestions:
In order to reduce and control these runs and stabilize and reinforce the Wales, at the start of the knitting, for approximately 30 knitted courses, cotton yarns are knitted in to the greige goods. This is also repeated at the end of the roll. This will ensure that no runs occur during the dyeing process thus reducing the fabric damage.
Corrective Measures
During the finishing process, in order to reduce the fiber slippage, the dyed fabric needs to be treated with an anti-slippage chemical through padding. This chemical is usually a solution of Colidal Silicate. Basically this chemical increases the fiber’s coefficient of friction and creates a non-slippage condition.
The application of this treatment might, however, affect the
softness of the fabric and must be used in small quantities.
All parts / accessories required to make machine operational on site
Additional accessories:
Frames up to 24 frames
Frame motion is pneumatic shedding
Methods:
This factory use to produce carpet by the loom. The producer
fulfill their work, they are also modified the the hand loom. But the process
of carpet produce is the same in the shuttle loom.
This loom uses one shuttle to produce one color of carpet.
To produce different design and color use to multi shuttle. This loom treadle
levers are control by the leg. This loom use maximum 10 heald frame. This loom
use threads (TC) yarn to work heald eye.
This loom has big flinch to protect the warp thread
selvedge. Also use long ring pipe to produce loop carpet design. After produce
loop formation design then cut the loop head to produce a new design (terry
towel). This loom has no picking stick
or rod because the workers are control pick by hand.
Weaving Related Defects/Problems
Mill Bars-
Definition and Causes:
A slight variation in the speed of the shuttles or other
devices that carry the yarns and their traverse action sometimes create weft
yarns (across the width of the fabric) of different lengths and tensions.
This is commonly referred to as Mill Bars.
During the dyeing process the uptake of dye in these areas
will be different and causes lighter or darker shade bands to appear on the
fabric.
Preventive Suggestions:
Monitoring the speed and controlling the tension of the weft
yarns are essential and an important part of the weaving process.
Corrective Measures:
For this problem no corrective measures are available.
Warp Lines-
Definition and Causes:
During the Warping process yarns are wound on beams at
regular and measured intervals and pre-determined spaces.
A slight discrepancy in these pre-set spaces causes vertical
lines to appear along the length of the fabric and parallel to the selvedges.
Preventive Suggestions:
Correct and precise warping is always a critical and
important part of the weaving process and needs to be closely monitored.
Corrective Measures:
For this problem no corrective measures are available.
Holes-
Definition and Causes:
Most holes which occur during the knitting process are a
result of what is known as “Drop stitch”.
This Drop stitch is normally caused by the sudden
dis-engagement of the needle at the knitting zone. The causes are:
Yarn’s dry condition where in certain cases it can produce
static charges causing the yarn to be repelled and thus miss the needle,
The malfunction of the Positive feed system which supplies
the yarn to the knitting elements at a steady and controlled rate, and
Excessive yarn slubs and thick and thin places.
Preventive Suggestions:
Regular maintenance and upkeep of the machine are essential.
The condition of yarns also needs to be evaluated.
Corrective Measures:
For this problem there are no corrective measures are available
