A Guided Tour of Our Yorkshire Factory

In News by Punch Creative

Here at Heckmondwike FB, we believe that where we are based says a lot about who we are as a company.

As the name suggests, our factory is located near Heckmondwike, a small town in West Yorkshire. Since the company was founded in the 1960s, our values have always been very straight-talking, honest and true to our Yorkshire roots.

Our emphasis on transparency and access to the highest quality materials have been key factors in creating the legacy that we now hold in the UK education sector and beyond.

So with that spirit in mind, here is a guided tour around the key processes we use to manufacture our fibre bonded carpets.

  • Arrival of the fibre

The first step in creating our carpets is receiving the shipments of fibres at our Goods Inwards department. Fibre is the basic material that a carpet is made up of, with over ninety percent of all carpets now crafted from synthetic fibres.

The fibres we receive are predominately polypropylene and nylon fibres which are then colour matched to make sure they are up to the highest standard.

  • Blend, blend, blend!

The fibres are blended together to create different bespoke mixtures of colours and textures for each range we offer. We don’t just mix colours, we also combine types of fibres in order to create material blends that have different textures and durabilities. The blending also opens up the fibres, preparing them for the next process; to be made into carpet.

  • It’s needle time

The fibres are further mixed ready to be carded; a process of separating the individual fibres using a course of dividing and redividing steps, which ultimately causes the fibres to lie parallel to one another, eliminating any remaining impurities.

In their carded form the fibres are presented to the first pre-needling process, where they are needled into a sheet with multiple layers. After this, they are further needled, which compresses those layers, forming a blank canvas for the designs.

Last in this stage, the needled carpet is structured by unique structuring needles, meaning it is essentially ‘imprinted’ with its pattern and texture.

  • Finishing touches

To ensure the highest quality end product, we apply a latex coating in our backing plant which further bonds the fibres. The carpet can be backed with a variety of different backing materials, depending on the final product required. We use a number of other different types of backing including foam, crumb and acoustic. For our carpet tiles, a bitumen back is added at our sister factory Paragon Carpet Tiles.

Finally, the finished carpet product heads to despatch, ready to be delivered across the UK to a variety of destinations including schools, offices, universities and apartment complexes – to name just a few!

All in all, we’re really proud of how we manufacture our fibre-bonded carpets in our Yorkshire factory. Especially as all of our products are quality tested to industry and environmental standards before being approved.

Why not order a free sample today to experience our high-quality carpets for yourself, or get in touch on 01924410544.