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Our Unique Process – From fleece to floor

Axminster Carpets has total ownership of every aspect of the manufacturing process – from fleece to floor.  This makes a world of difference both to the impact and the long term performance of an installation.

Axminster Carpets™ incorporates more that 90 per cent British wool in its carpets.  This is resilient, hardwearing British wool most suited to Axminster carpet weaving, with characteristics which distinguish British wool as a premier carpet fibre and have contributed to the worldwide reputation enjoyed by Axminster Carpets™.

The most important element of the carpet is the yarn, which is why in 1950 we invested in our own spinning and dyeing plant in Buckfast, Devon. Today, Buckfast Spinning Company is one of finest spinning mills in Europe and supplies all the yarn for Axminster Carpets.

1. On arrival at Buckfast, the raw wool is sorted according to fibre length and colour and a six stage washing process removes dirt, grease and other impurities.Read more >>
2. The wool is dried and any dust is extracted, before it is blown into large storage bins, to relax and regain its original structure. It is then lightly lubricated, baled and left to condition process before the next process – carding.
3. Carding is a precisely monitored operation using a series of progressively finer spiked roIlers to comb out the wool fibres into a fine, uniform web. The wool is then divided into narrow strips, or ’slubbings’, which are then spun at more than 5000 rpm into a single ply yarn.
4. By twisting the strands together, as two or more ply, additional strength and density is acquired by the yarn, affecting the eventual weight and quality of the finished carpet.
5. Colourfast dyes are used to produce delicate subtle shades and colours and a computerised system ensures precise matching to the colour required.
6. Once dried, the hanks are allowed to cool and condition naturally before being wound onto more manageable ‘cones’ and packaged for dispatch to the weaving looms at Axminster. Several thousand kilos of yarn make this journey every working day.
7. The carpet is brushed to remove any foreign matter, and squared for alignment and symmetry. After further 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.
8. To ensure perfection, a meticulous final examination is carried out by eye.
9. 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.

With a unique combination of six pitch and eight pitch electronic Jacquard looms, the company is able to produce a considerable range of specifications to meet the needs of any client, and offering the opportunity to develop bespoke designs.