Summer training report about

Oriental weavers
Submitted by
Mahmoud khaled el-saued 20160954

Submitted to
Dr. Abdo Abdallah
Dr. Ahmed said
Eng. Mohamed Adel

June/July/2018
Table of contant
Table of figure
 Chapter one
Introduction about Oriental weavers
1.1 history of the company
Oriental Weavers Group is one of the world’s largest carpet and rug
manufacturers. Based in Cairo, Egypt, the Group has manufacturing
facilities in three countries and distributes its products in more than
130 countries worldwide.
Oriental Weavers (OW) is one of the most recognized brands in the
machine woven rug and carpet industry today. Established in 1979 by
Mr. Mohamed Farid Khamis, a leading Egyptian entrepreneur and
industrialist, the company has grown under his leadership to become
one of the largest and fastest-growing machine made rug and carpet
manufacturers in the world.
A true Egyptian success story – and building on Egypt’s long textile
tradition which dates back thousands of years – Oriental Weavers has
grown to become a vertically-integrated, multinational floor coverings
producer based in Egypt’s Tenth of Ramadan City, with additional
production facilities in China and the United States. The company
exports more than 50% of its production to more than 130 countries
on six continents through a distribution network that includes offices
in the United Kingdom, Egypt, China, the United States, and Canada.
OW is the acknowledged leader in design, quality and innovation
within the industry. With a simple vision, the company has become a
leading worldwide exporter and by far the largest player in the
Egyptian market.
 OW is the acknowledged leader in design, quality and innovation
within the industry. With a simple vision the company became a
leading worldwide exporter and by far the largest player in the
Egyptian market.

OW is the flagship company of the Orientals Group, which is a

multinational organization that incorporates several companies
dedicated to the production of woven rugs and carpeting, along with
related raw materials. OW, located in the 10th of Ramadan City near
Cairo, is completely vertically integrated thus providing the company
with the advantage of manipulating and producing fine fibers, and
manufacturing the world’s most innovative rugs and carpets. Most of
OW’s raw materials are produced within its subsidiaries, allowing it to
pass on the advantages of complete vertical integration to all its
customers.

1.2 Scope and Focus of this Study

1.3 a
1.4 a
1.5 a
1.6 a
1.7 a
1.8
 Chapter two
Types of carpets
2.1 example of carpets that madden around the world
It is an unsolved mystery that exactly when and where was the first
carpet woven or where did this art originated. However, experts say
that the earliest carpets may have been first produced in Persia (Iran),
Turkmenistan, Central Asia, Mongolia and China (these places are often
referred to as the “CARPET BELT”.
Traditionally, Turkish women have woven carpets of rich colors, warm
tones, and extraordinary patterns with traditional motifs, which have
contributed to the reputation that Turkish carpets have maintained
since the 13th century.
Carpet means one type of thick fabric equipped with extra yarn on its
surface-fabric, which is termed as 'Pile'. This pile is produced by the
support of warp yarn or support of weft yarn. The term was also used
for table and wall coverings.

Carpets are used in households, offices, hotels, functions, occasions,

public gatherings and many more places to list. Apart from beautifying
the surroundings, they are prominently used to pronounce the theme.
To satisfy an immensely varied target market, there exists a huge range
of carpets encircling all kinds of classifications in carpet manufacturing.
Be it according to type of fabrics or according to design or weaving
techniques, carpets are available in various ranges to fulfill the market
demands.
Most commonly used fibers to make carpets are wool (warm and
durable), silk (most exotic), jute, some synthetic fibers like nylon,
polyester, olefin, and acrylic, out of which polyester is durable of all.
Bamboo carpets and Coir carpets form a different range of eco-friendly
carpets.
One can select out of almost twice a dozen designing patterns of carpets.
Ranging from the oldest and plushiest Turkish and Persian carpet to
colorful Kashmiri carpets, they encircle a variety of cultural influences
inscribed in designs.

Only a broad and vague classification can be done according to the

weaver’s skill. Generally hand knotted, hand tufted and hand woven
carpets with some more types constitute this category.
Another category rather a new one is of Bonded Carpets or ‘Non-Woven’
carpets. Easy processing, comparatively low cost and durability are
some of the factors that contribute to their increasing popularity.

Carpets and rugs enhance the beauty of homes or commercial spaces.

Technically, the two terms are used interchangeably across the world.
For instance, in America a carpet would mean a floor covering that
applies to wall-to-wall flooring and rugs are area specific or movable
floor covering used as centerpiece on the floor. While in India both
terms are used to denote any floor covering.

Until 18th century, carpets were widely used as table and wall coverings.
They were later invented as floor coverings. Known to accentuate the
theme of a room, a carpet can be hand-knotted, tufted, machine made
or felt wool. A carpet can be made from many single or blended natural
and synthetic fibers that may add more durability and tone up the
appearance.
2.1.1 The various types of carpets available can be classified as under:
• On the basis of fiber
• On the basis of designs
• On the basis of weaving techniques

2.2 And now we can classify carpets material to :-

Carpet is made from various synthetic and natural fibers. Each has
different characteristics.
 Nylon is the most popular. It’s durable and resistant to wear. It’s
not good at fighting stains, so some varieties include a stain-
resistant treatment.
 Olefin is resistant to moisture, mold, and mildew and makes a
good carpet for basements and outdoors. It’s tougher than nylon,
but not as comfortable to walk on.
 Acrylic is often used as an inexpensive alternative to wool. It’s not
widely available.
 Wool is the premier carpeting and the only natural fiber made into
carpets. It’s durable and stain-resistant, and it’s considered an
ecofriendly floor covering.

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spaces/floors/your-guide-to-the-different-types-of-carpet
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 Chapter three
Manufacturing of carpets

Figure
3.1 The Manufacturing Process
The process of manufacturing tufted carpets can be explained in the
following steps:
Step 1: Preparing the yarn
• First, the synthetic yarns arrive at the carpet manufacturer either in staple
fibre form or in bulk continuous filament form
• The staple fibres, which are an average of 7 inches (18 cm) long are
generally loose and are individual strands that arrive in bales. Several bales
are blended together into one batch in a hopper.
• Then, these strands are lubricated and are spun into long, loose ropes
called slivers by a carding machine. The slivers are then pulled, straightened,
and spun into single yarn that is wound onto spools.
• Both the single-ply staple fibres (now spun into filament) and the bulk
continuous filament is then twisted together to form thicker two-ply yarn
suitable for tufting.
• The yarns are then steamed to bulk them, and then heated to 270-280°F
(132-138°C). This heat setting causes the yarn to maintain its shape by fixing
its twist. After cooling, these yarns are wound onto tubes and transported to
the tufting machines.
 figure

Step 2: Dyeing the yarn

• Generally, most carpets are dyed after tufting yet sometimes the yarns are
dyed first. The methods include putting 500-1,000 pounds (227-455 kg) of
fibre into pressurized vats through which treated dyes are circulated, or
passing the fibre continuously through the bath, or passing skeins of yarn
through the vat of dye.
• The yarn can also be put on forms, and the heated dyes can then be forced
under pressure from inside the forms to coloured the yarn.
• Another method passes the yarn through printing rollers, while yet
another involves knitting the yarn onto a form that is then printed with dyes
before the yarn is unraveled. All yarn that has been dyed is then steamed,
washed, and dried.
 figure

Step3: Tufting the carpet

• At this stage, the yarn is put on a creel (a bar with skewers) behind the
tufting machine and then fed into a nylon tube that leads to the tufting
needle.
• The needle pierces the primary backing and pushes the yarn down into a
loop. Photoelectric sensors control how deeply the needles plunge into the
backing, so the height of the loops can be controlled.
• A looper, or flat hook, seizes and releases the loop of yarn while the
needle pulls back up; the backing is shifted forward and the needle once
more pierces the backing further on.
• Inorder to make a cut pile, a looper facing the opposite direction is fitted
with a knife that acts like a pair of scissors, snipping the loop. This process is
carried out by several hundred needles (up to 1,200 across the 12 foot [3.7
ml width), and several hundred rows of stitches are carried out per minute.
Thus, one tufting machine can produce several hundred square yards of
carpets per day.

Step 4: Dyeing the tufted carpet

• Solid coloured carpeting: For this carpet of several standard roll lengths is
sewn together to make a continuous roll, which is then fed into a vat. The
vat is filled with water, which is first heated before dyes and chemicals are
mixed in. The mixture is then slowly brought to a boil and cooked for four
hours approx.
• Another method of making solid coloured carpet is to sew several rows
together to make one continuous roll, which is then fed under rods that
bleed the coloured into the pile. After dyeing, the carpet is then steamed to
fix the coloured, excess coloured is washed off, and the carpet is dried and
put on a roll.
• Printed Carpets: Inorder to make printed carpet of various designs, white
carpet passes under screens in which holes in the desired pattern have been
cut. The desired coloured is squeezed through the holes in the screen, and
the carpet is advanced 36 inches (91 cm) to a different screen that applies a
new coloured in a different design through the screen. Up to eight coloureds
can be applied with this method.
• Another method of dyeing printed carpet is to pass it under embossed
cylinders that have raised portions in a design that press colour into the
carpet. Each cylinder provides a different design for a different coloured.
After dyeing, the printed carpet is steamed, excess dyes are washed off, and
the carpet is then dried and put onto rolls to go to the finishing department.

Step 5: Finishing the carpet

• The ends of the dyed carpet are first sewn together to form a continuous
belt. This belt is then rolled under a dispenser that spreads a coating of latex
onto the bottom of the carpet.
At the same time, a strong secondary backing is also coated with latex. Both
of these are then rolled onto a marriage roller, which forms them into a
sandwich and seals them together. The carpet is then placed in an oven to
cure the latex.
• The completed carpet is then steamed, brushed, vacuumed, and run
through a machine that clips off any tufts that rise above its uniform surface.
The carpet is then rolled into 120 foot (37 m) lengths that are then packaged
in strong plastic and shipped to either the carpet manufacturer's inventory
warehouse or to a retail carpet store.

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Manufacturing.htm
Hand-made carpets are technically very different from machine-made
carpets. As it is quite relevant from their names, hand-made carpets are
woven by hands while machine-made carpets undergo treatments by
various machines
• Process of hand-made carpets
• Process of machine-made carpets

Hand-made V/s Machine-made carpets

Carpet is a textile floor covering that is fixed to the floor surface and extends
wall to wall. Such a textile floor covering is manufactured in two ways: hand-
made or machine-made.
One of the most prominent differences between hand-made and machine-
made carpets is that the former holds a valuable impression. The other main
difference between these two types of rugs is the actual manner of
construction. Machine-made rugs consist of plastic derived fibers being
glued onto a strong plastic base which makes them initially very durable, but
over time the adhesive degrades and the fibers detach easily from the base.

It is said that for rooms with modern designs or active areas with high traffic
or children, machine-made rugs with contemporary designs are excellent.
On the other hand, there is a common misconception that hand-made
oriental rugs are delicate and not durable. Their ornate designs and soft feel
often deceive many.

More clarity on the differences can be explained in terms of:

• Knots used
• Sides and Ends sewn
• Back of the carpets
• Materials used
• Touch
• Manufacturing process

Knots
Machine-made rugs and carpets are not woven by hand but are loomed by a
computer generated system or apparatus. There are no knots in machine-
made rugs. Whereas in a hand-made rug, each knot is hand knotted and
tied. In machine-made carpets, threads are glued or looped onto a hot latex
(plastic) backing which cools and hardens. They show a complete and rigid
uniformity in manufacture which transforms into a static design. Machine-
made rugs generally lack spontaneity and human touch. Also read various
hand-knotting styles

Sides and Ends

In a hand-made or hand-knotted rug, the fringe is ‘part’ of the rug. The
fringe is not sewn on as an extension, as is the case in machine-made rugs.
Machine-made rugs always have ‘serged’ sides or machine stitching on both
sides of the rug, as opposed to a hand-knotted which will be irregular and
imperfect.

Back
In power loomed or machine-made rugs the stitching on the back is very
consistent. They have extremely regular knots and even structure remains
identical in all parts of the carpet. On the other hand, in hand-knotted rugs
the stitching varies slightly due to different tensions on the wool as people
hand-tie the knots. Most hand-made rugs and carpets are covered with a
cotton or canvas backing.

Materials
Acrylics and other chemically processed materials are usually used to make
machine-made carpets. Hand-knotted rugs and carpets use pure organic
wools.

Touch
You can also differentiate a machine-made and hand-made rug simply by
touching. If you place one finger on the front of a machine-made rug and
your thumb on the back and pinch tightly, the rug will compress greatly and
you will feel a sensation going right through one side to the other side. On
the other hand, while pinching hand-made rugs you will feel much more
body and substance