Construction methods

In an axminster gripper weave, cut tufts of yarn are inserted at the point of weaving by means of grippers. For each tuft to be inserted along the width of the carpet, there is a corresponding metal gripper which rises from the bed of the loom to grip the appropriate coloured end of yarn from the vertical yarn carrier. A knife blade slices the tuft to the correct length, the gripper then returns to the bed of the loom and places the tuft in the appropriate position, the weft shots of the backing yarns then bind it into place.

A beater bar pushes each row of tufts and weft shots tightly
against one another to form the carpet. The “beatup” (rows) can vary from as low as 5 to 14 rows per inch, or even higher if required. Different coloured ends of yarn (according to design) can be selected from the yarn carrier, which is raised or lowered by means of a jacquard (punched card) mechanism. Many different colours can be used in this weaving method. More modern looms have electronic jacquards which enable them to produce very complicated designs with almost infinite pattern repeats.

A traditional wilton weave carpet is one in which the pile threads run continuously into the carpet and are raised above the surface of the integral backing by means of wires or hooks. Wilton carpets are often cut or loop products and different yarn types can be used to produce different surface textures. Wilton weaving is not as versatile as axminster for the production of patterned carpets, due to continuous yarns that create waste yarn on the back of the carpet.

Woodward Grosvenor wilton carpets are woven on looms designed and built by our own engineers in our own factory. They differ from traditional wilton looms as they have no “dead” or wasted yarns in the back. These advanced design looms weave two carpets as a sandwich, know as "face to face", which is then sliced into separate rolls. As with traditionally woven wilton carpet, Woodward Grosvenor face to face looms produce a durable woven product, which is hard wearing and dimensionally stable. The carpet does not suffer from the delamination and stability weakness often associated with tufted carpets.

A number of needles arranged across the width of the machine stitch yarns into a primary backing cloth, which is fed through the machine. Once the pile has been created, it is held in place by a latex backing. Secondary backings can be applied to add weight and handle to the product. Both cut and loop can be produced in the same carpet.

It is basically a basket weave effect. With each different shot the polypropylene and wool yarn wefts are either raised or lowered for the wool warp yarns to pass under or over them.

Our Natural Base products are manufactured using a traditional woven construction known as flatweave to give an unusual basket weave effect with a latex backing. These are made using four different plant fibres:

Sisal, Seagrass, Coir and Jute

For more information on each of these please take a look at raw materials.