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After tufting, the next process is dyeing. Most carpet is produced from natural or white yarn (except solution dyed products) and is stored as greige goods prior to dyeing. The greige goods are weighed after the tufting process. This weight is used to determine the amount of dye to use and is the starting point for the dye formula.
1. This process usually starts at a lay-up table where the 400 to 600 foot long rolls of greige goods are stitched together to reach the length required for that color.
2. The greige goods then pass through a pre-steamer, which softens the pile, and on to a rinse or wet out position, which removes any identification dye from the yarn.
3. The greige goods then move on to the dyeing station. The actual process for applying the dye varies and depends on the type and blend of yarn as well as the type of dye. In some machines, the dye flows onto the carpet from a dye pan and a blade spreads, distributes and accurately controls the amount of dye applied to the carpet surface. In others, the dye is applied by spraying it onto the carpet. There also is the process where the carpet is run through a trough containing the dye.
4. Next the carpet travels to a steaming station which sets the color.
5. Stain Release treatments can be added after the color is set.
6. Then the carpet is rinsed in wash boxes that takes out all the loose dye or strong chemicals.
7. If fluorocarbon treatment is required, it is done at this stage just before drying. Some manufacturers apply this treatment in the finishing operation.
8. The dyed carpet then moves through the drier where the excess water is extracted, the pile fluffed and the carpet dried.
9. Dyed, unbacked carpet is rolled and ready for the finishing process.
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