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Mountville Mills, Inc. Plant Tour

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Mountville Mills, Inc. Plant Tour

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  1. Mountville Mills, Inc.Plant Tour

  2. Two ManufacturingLocations Dalton, GA LaGrange, GA

  3. How Carpeted Mats are Manufactured • 3 Major Components of Mats • Yarn • Substrate • Rubber

  4. 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

  5. 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

  6. 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

  7. 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

  8. Static Dissipative Carbon Fiber Filaments 250x

  9. Exceeds IBM static propensity requirements Passes AATCC134 Electrostatic Propensity Test

  10. 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

  11. Roll of Substrate on tufting machine

  12. Acid Dyed Carpet Tufting Process Close Up of Needles Carpet Tufter

  13. Acid Dyed Carpet Dyeing Process

  14. Solution Dyed Carpet Tufting Process

  15. Logo Mat Options • ClassicCreations™ - Acid Dyed / Graphic Tufted Process • CompuTuft™ - Solution Dyed / Graphic Tufted Process • ClassicImpressions™ - Acid Dyed / Digital Printing Process

  16. Graphic Tufted Process • Acid Dyed and Solution Dyed Options • Computer Generated process • Yarn is tufted (sewn into the substrate)

  17. Tufted Logo Mat

  18. 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’

  19. Logo Image Created on the Zimmer Printer

  20. Logo Image Created on the Zimmer Printer

  21. Product Knowledge100% Nitrile Rubber Backing • Slip resistant • Makes the product washable • Nitrile rubber is oil/grease resistant • Reinforced borders minimize tears

  22. 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.

  23. 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

  24. Mat Trimming Process • After the rubber backing is applied the mats are trimmed • Curved Corner Option

  25. Mat Perforation Process • All mats are perforated to reduce the moisture in the extraction process • Less moisture – less drying times

  26. 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

  27. A Thank you & Good Job ! Now let’s move on to review Product Features & Benefits