Carpet Manufacturing

SUB SECTOR: CARPET BACKING

Carpet backing is extremely important, providing shape, structural stability, and protection to the carpet. There are a number of different styles of carpet backing, and it can be made from an assortment of materials, ranging from natural fibers to polyurethane.

The two main components of carpet backing are the primary backing, which forms a structural element of the carpet—the coarse material through which the carpet fibers are looped or interwoven. Secondary backing is not structural, but provides support to the overall carpet, and it may help to insulate the carpet from moisture, bacteria, and mold which could seep up from the floor below.

Application – Conveying of Carpets and Carpet Tiles while Backing is Applied

In the manufacture of carpet and carpet tiles, the reverse side of flocked and woven carpet products is usually coated with PVC, bitumen and rubber and layered with non-woven fabrics.

PTFE- Coated conveyor belts are used to apply the PVC polymers and oils such as bitumen to the back of the carpet and carpet tiles.

Canada Plastic & Belting Inc provides PTFE Coated Belts that withstand the high operating temperatures and resist adhesion and chemical bonding of polymer and oil-based backing materials and compounds.

SUB SECTOR : POLYMER BASED CARPET UNDERLAY

Carpet underlay is the layer of Polyurethane foam, sponge rubber or crumb rubber cushioning that is laid beneath carpeting to reduce carpet wear and to provide insulation against sound, noise, moisture and heat.

Application – Conveying the Underlay Material for Cooling and Adding Texture

During the production of Polymer-based carpet underlay, a conveyor belt presses the polymer (either with a non-woven or woven Hessian backing) to a steel chain belt or impression roller to create a pattern on the non-backing side. The use of specialized conveyor belts, such as PTFE Coated Belts, offers the necessary non-stick properties to allow a clean release of the product.

Application – PTFE Glass Tape used to Cover Heated Drums

Heated drums are used to melt and secure the polyethylene film to the recycled foam particles to form sheeting. Our PTFE Coated Fiberglass tape is used for its release characteristics. This allows the poly to apply evenly without sticking to the heated drum. The relatively thin nature of the PTFE tape allows for excellent heat transfer to melt the poly and bond the foam – thus forming sheeting.

Entry Mat

SUB SECTOR: WALK OFF / ENTRY MATTS

Walk Off/ Entry Mats are usually found just inside the doors of retail/commercial buildings and workplaces. There are various styles from plain black or brown, which are most common, to more stylized and even customized designs that may include a popular brand or company logo. In most cases, these mats will have rubber textured, non-slip backings.

Application – Conveying of Mats while Backing is Applied

Canada Plastics & Belting Inc supplies PTFE Coated Conveyor Belts used to convey the mats while anti-slip polymers are applied to the reverse side. Our PTFE Coated Fabrics are used as press coverings (Press Sheets) to protect the machine press as the polymer backing is being applied. While the polymer is still wet, the Press Sheets are placed on top of the mats and the mat is then pressed with a perforated aluminium plate to create the non-slip backing on the Polymer.

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