Printed Carpet Production Process
- Base Cloth Preparation
Polyester, polypropylene or Nylon Carpet base cloth is selected, followed by warping, weaving or setting, to ensure the base cloth is flat and with uniform tension.
- Pre-treatment
The base cloth is pre-washed, dried and set to remove oil, dirt and lint, so as to improve dyeing uniformity and dimensional stability.
- Pattern Design & Screen Making
Patterns are designed according to requirements; after color separation, printing screens, rotary screens or digital printing files are prepared for dyeing.
- Printing & Dyeing
- Rotary Screen Printing: Synchronous multi-color printing through rotary screens for continuous production.
- Digital Printing: Patterns are directly printed onto the base cloth, suitable for small batches and various designs.
The color paste or ink penetrates evenly into the fibers to form clear patterns.
- Steaming & Color Fixation
The Printed Carpet enters a steaming machine. High-temperature steam fully bonds the dyestuff with the fibers, resulting in higher color fastness.
- Washing & Drying
Washing removes floating color, excess paste and impurities. The carpet is then dried and tentered to prevent shrinkage and deformation.
- Back Coating
Latex or SBR adhesive is coated on the back of the carpet to form an anti-slip and wear-resistant backing, enhancing stiffness and service life.
- Secondary Drying & Setting
The backing adhesive is dried to further stabilize dimensions, making the carpet surface flat and with better hand feeling.
- Cutting, Edging & Trimming
The carpet is cut to size as per customer requirements, then processed with edge binding, overlocking and trimming to improve appearance and durability.
- Inspection, Packaging & Warehousing
Color difference, pattern, color fastness, appearance and other indicators are inspected. Qualified products are rolled or packed, then stored and delivered.