Our Unique Process – From fleece to floor
Axminster Carpets has total ownership of every aspect of the manufacturing process – from fleece to floor. The company uses more than 90% British wool, carefully selected by our specialist buyers.
We only use pure new wool in our 100% wool yarns ensuring the very best environment for passengers, the lowest carbon footprint, and carpets that retain their good looks for longer. We also offer 80:20 mixes for top of the market aesthetics and comfort, combined with the particular performance qualities of nylon.
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.
- On arrival at Buckfast, the fleeces are opened by hand and mechanically stretched out. They are then sorted into pre-determined quantities to provide the most suitable mix for carpet yarn.
- The blended wool then passes on to a six-stage washing process called ‘scouring’ when dirt, grease and other impurities are removed before final washing.
- Once all the grease and impurities are removed, the wool passes onto the next stage which is ‘carding’. A series of progressively finer spiked rollers tease out the wool fibres to a uniform web. The finer strands of carded fibres or ‘slubbings’ are then loaded onto a spinning frame.
- The woollen strands are spun at more than 5,000 rpm to produce single-ply yarn. By twisting the strands together as two or more ply, additional strength and density is acquired by the yarn. We even produce a ‘6-ply Cabled-Tec™ yarn’ for more demanding products.
- The spun yarn is then moved on to the Dye house. Colourfast dyes are applied under pressure to produce a wide variety of subtle colours.
- Large driers are used to reduce the moisture content before it is wound onto cones and sent to Axminster for final carpet weaving.
We can also offer transportation compliant tufted variations for cabin locations and particularly price sensitive applications. We have a QMS at every stage of production and we are proud to hold ISO 14004 accreditation.
With a unique combination of six pitch and eight pitch electronic Jacquard looms up to I5ft (4.57m) wide, the company is able to produce a considerable range of specifications to meet the budgets and needs of any client, and offering the opportunity to develop bespoke designs with remarkable clarity and quality.
