An Axminster™ carpet is synonymous with quality and luxury, and all authentic Axminster™ carpets are still woven using natural materials and traditional methods.
Part of the base of the carpet is the Jute ‘weft’ which is passed between alternate parallel cotton ‘warps’. The wool yarn is fed into carriers which are controlled by a jacquard. A colour is selected by the jacquard, which causes the corresponding yarn to be offered up by the carrier to a gripper. The grippers then draw the pre-selected lengths of yarn which are cut by a series of knives. The resulting tufts are positioned between the warps by the grippers, and retained by each pass of the weft.
In this way a woven lattice of tightly packed cords and wool tufts build up to form a carpet, at the rate of three to five yards per hour, under the expert supervision of the weaver.
The quality of the carpet is determined by the number of tufts per square inch, the count or weight of the yarn and the length of pile.
Wilton carpet, like Axminster™ carpet, is woven. However the difference between the two methods is the way in which the carpet is woven. Whereas the Axminster™ yarn is cut into tufts and then held in place by the weft, the Wilton carpet yarn is a continuous strand woven all the way through.
The state of the art Wilton looms at Axminster use a maximum of five colours, producing cut or loop pile textured carpet. It is the preferred flooring for some commercial installations and most transportation applications as it is hugely stable and extremely hard wearing. Axminster Carpets currently manufactures Wilton carpet for the majority of UK rail companies and have worked with many global airlines including British Airways and Virgin.
Tufted carpet is the most economical of the carpet producing methods. Unlike Axminster and Wilton carpet, a tufted carpet is produced by inserting yarn into a pre-existing backing using needles. This method is an extremely fast (one roll of Axminster might take 8 hours to make whereas one roll of tufted takes approx 1 hr) way of manufacturing carpet. While it is true that a tufted carpet is not a woven carpet, at Axminster Carpets, all the yarn used is specified by our experts and spun in the UK, ensuring that only the finest and most durable quality is produced.
Because Axminster Carpets places great importance in specifying the yarn used to make its high quality carpets it works in partnership with leading UK specialists.
Flatbed Weave Carpet:
The flatbed weave carpet is a fashionable textured approach. This design requires the use of unique yarn technology and produces a carpet with superior strength and style. A flatbed weave carpet can be woven over many weft insertions, allowing the creation of a larger, flatter and more textured looking loop pile.
Axminster Carpets uses more than 90% British wool in its carpet production.
Once at Axminster, the yarn is woven into carpet using either six pitch or Axminster’s special eight pitch looms. Once the weaving is completed, the carpet is brushed to remove any foreign matter, and squared for alignment and symmetry. After steaming to burst open the lush woolen pile, a coating of vinyl is applied to the back of the carpet to assist tuft retention and ease cutting and fitting. Further brushing is followed by a second and final tip shearing operation to ensure a smooth, level finish.
To ensure perfection, a meticulous final examination is carried out by eye.
Barcode identification enables total traceability of the carpet's processes and materials, at this and every other production stage. Carpets are cut and sized to order requirements, before rolling and final packaging.