How to Start a Rug Manufacturing Business
There are a wide range of businesses that are easy to set up and start. One popular option is rug manufacturing, as there is always a demand for high-quality rugs. However, to be a successful rug manufacturer, you must understand the rug creation process. This includes knowing about raw material suppliers, the production process, machinery requirements, and more.
Once you have an understanding of the process, you can start your business quickly and easily. A wide range of area rugs are on the market in various designs, colors, shapes, and styles. People use rugs in their homes, and offices to add comfort and complete their aesthetic. Therefore you should consider what styles and material types are most popular.
Rugs have been in use for many decades, in fact the earliest people often used animal skins and grass to cover their dirt floors. Then, once spinning wool and cotton became commonplace, these materials were used to make floor coverings. The weaving of cotton and linen to create the base of a rug started in Turkey, China, India, and Iran. They often even used silk and wool to make more luxurious rugs. Nowadays, rugs are often made using a combination of these cotton and linen bases with the silk and wool luxurious pile on top.
Rugs used to be primarily handmade, but as time has passed technology is taking over in the form of machine manufacturing. Machine manufacturing has made rug production easier than ever before. A wide range of companies have opened and are producing hundreds of rugs in less time than it would take to make one rug by hand.
Below are the essential details you should know before starting a rug manufacturing business. So if you are looking to jump into rug manufacturing, take note of these important steps:
First of all, you should collect all the required information and create a tracking sheet. Here are some important questions to ask and information to include;
- Where can you find the required machinery?
- How much will the machinery cost? Be sure to include the shipping costs in this.
- How much do you need to invest to open your factory?
- Who are the suppliers of the raw materials?
- What size labor force do you require to work in the factory?
- How will you handle marketing for the business to generate sales?
- How many employees will be you need for the administrative functions of the business?
Start to do your research and find answers to all of the above questions. As you find the answers, you can begin building the business, and business plan. As with any business, this will take a lot of time, work, and investment at the beginning.
Manufacturing Process of Rugs
Finding machinery may not be as difficult as you think as many rugs are already tufted here in the US. Next is to decide on the first rug you want to produce. You can create rugs in almost any size and shape you like. These shapes include circle, floral, triangle, long, square, rectangle rugs. You can also create unique designs similar to Turkish and Persian rugs. While choosing your first product to manufacture, consider the manufacturing process as detailed below.
Preparation of Yarn
The first step in rug production is preparing the yarn. This is a crucial step as this is the base of your product. Synthetic yarns will arrive in bulk as a fiber form. These must be blended together to create a thicker thread. Once the fibres are blended together, they will be lubricated and spun to create long ropes. These ropes are pulled, spun, and straightened to become the base yarn. This is then twisted together and heated to temperature to lock the coiled shape. Once the yarn is cool it is ready to use for tufting.
Dyeing of Yarn
If you create a single color rug, the rug will be dyed after the tufting process. However, if you are creating a patterned rug, the yarn should be dyed first.
Most factoring use vats to dye the rugs. Dyes are pressurized to extract the color through heat within the vats. Once the dye is at the correct temperature the yarn is added. Once dyed, the yarn is put through rolling machines to extract excess color and to help completely dry the fibres.
Tufting of Rugs
First the yarn must be loaded onto the creel that is behind the tufting machine. It then passes into a nylon tube there the tufting needle is. A photoelectric sensor controls the needle. The sensor controls how deep the needles go, this must be adjusted be rug to ensure accurate tufting. In one day, you could potential produce 20 rugs per machine, whereas handmade rugs take a few weeks to a month to complete.
Finishing of the Rugs
To finish, the dyed rug should be sewn together; then attached to the finishing belt. This belt will spread a latex paste on the bottom of the tufted rug to secure the stitching. At the same moment, the secondary plain cotton backing will be coated with latex. The tufted rug and the plain backing are then sealed together by machine.
The finished rug is then vacuumed, brushed, and dried. Rugs are then packed into protective plastic wrap and sent to distributors or directly to customers.
Now that you know the basics to rug manufacturing, you have a better understanding if you wish to start your own business. Just remember to do your research, and budget accordingly.