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Mountville Mills, Inc. Plant Tour. Two Manufacturing Locations. Dalton, GA. LaGrange, GA. How Carpeted Mats are Manufactured. 3 Major Components of Mats Yarn Substrate Rubber. The Nylon Yarn. Acid Dyed or Solution Dyed Options High Twist Yarn

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Two ManufacturingLocations

Dalton, GA

LaGrange, GA


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How Carpeted Mats are Manufactured

  • 3 Major Components of Mats

    • Yarn

    • Substrate

    • Rubber


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The Nylon Yarn

  • Acid Dyed or Solution Dyed Options

  • High Twist Yarn

  • Brushes soil and dirt from the soles of shoes

  • Allows dirt to filter to the base of the carpet

  • Prevents crushing of the carpet


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Acid Dyed Nylon Yarn

  • Starts as white yarn

  • Color is added after the yarn is produced

  • Vibrant colors

  • Excellent color and wash-fastness

  • Protected by Stain Stopper Treatment


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Solution Dyed Nylon Yarn

  • Color is added when the yarn is extruded

  • Excellent color-fastness when the mats are exposed to direct sunlight

  • Excellent wash-fastness when the mats are exposed to high temperature washings


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Product KnowledgeStatic Dissipative Feature

  • Static electricity creates safety hazards

  • The nylon yarn contains carbon filaments that absorb the static charges

  • Regular washings will not diminish its effectiveness


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Static Dissipative

Carbon Fiber Filaments 250x


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Exceeds IBM static propensity requirements

Passes AATCC134 Electrostatic

Propensity Test


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Product KnowledgeNon-Woven Polyester Substrate

The Backbone of the mat!

  • The yarn is tufted into the substrate

  • This substrate creates a stronger bond between the carpet and the rubber

  • Reduces fraying on the edges of the mat

  • Resistant to high temperature drying

  • Reduces linting

  • Prevents rippling



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Acid Dyed Carpet Tufting Process

Close Up of Needles

Carpet Tufter



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Solution Dyed Carpet Tufting Process


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Logo Mat Options

  • ClassicCreations™ - Acid Dyed / Graphic Tufted Process

  • CompuTuft™ - Solution Dyed / Graphic Tufted Process

  • ClassicImpressions™ - Acid Dyed / Digital Printing Process


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Graphic Tufted Process

  • Acid Dyed and Solution Dyed Options

  • Computer Generated process

  • Yarn is tufted (sewn into the substrate)



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Digital Printing Process

  • Creates 3D images

  • Prints fine detail

  • Up to 300 colors

  • Colors can be phased in

  • Fully launderable

  • Sizes to 6’ x 40’


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Logo Image Created on the Zimmer Printer


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Logo Image Created on the Zimmer Printer


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Product Knowledge100% Nitrile Rubber Backing

  • Slip resistant

  • Makes the product washable

  • Nitrile rubber is oil/grease resistant

  • Reinforced borders minimize tears


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Vulcanization Process

  • After the carpet is tufted it is vulcanized to the rubber.

  • Reinforced rubber strips placed around the perimeter of the mats to strengthen the product

  • Various rubber backing options are available.


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Rubber Backing Options

  • Standard Mill Thickness – 52 mils in the body / 94 mils on the border

  • 65 Mil Option – 65 mils in the body / 107 mils on the border

  • 90 Mil Option – 90 mils throughout

  • Picture Frame Option

  • Suction Back Option


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Mat Trimming Process

  • After the rubber backing is applied the mats are trimmed

  • Curved Corner Option


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Mat Perforation Process

  • All mats are perforated to reduce the moisture in the extraction process

  • Less moisture – less drying times


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Mat Shipment Times

  • All mats are rolled for ease of handling at your facility

  • Standard Orders less than 3 working days with or without property marks

  • Logo mats within 5 working days


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A

Thank you & Good Job !

Now let’s move on to review Product Features & Benefits


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